Bolens 24638B Owner's Manual
Contents
1. COLOR 2 1 2 Cylinder Comp 1 717 0816 2 720 0157 3 737 0196 4 719 0270 5 738 0601 6 749 0663 7 711 0628 8 712 0267 9 736 0119 10 781 0021 11 781 0069 12 781 0038 13 710 0298 14 736 0158 15 712 0337 16 712 0798 17 736 0169 18 735 0144 19 738 0143 20 781 0024 21 738 0140 2 732 0352 29 30 734 0736 31 750 0118 32 710 0599 33 756 0425 34 754 0278 35 781 0008 36 736 0119 37 710 0152 38 756 0426 39 710 0938 40 736 0105 41 710 0649 42 712 0123 43 710 0376 144 736 0119 747 0458 PARTS LIST FOR MODEL 638 LOG SPLITTER Grip 90 Elbow Adapter Pusher Plate Shoulder Bolt 5 8 Dia x 660 Lg 1 2 13 Thd Engagement Handle Adjustment Ferrule Hex Nut 5 16 18 L Wash 5 16 1 D Strainer Tube Tank Ass y Comp Wedge Ass y Hex Bolt 5 8 18 x 3 50 Lg Grade 5 L Wash 5 8 1 0 Hex Nut 5 8 18 Thd Hex Nut 3 8 16 Thd L Wash 3 8 D Rubber Wash Shoulder Bolt 498 x 340 Engagement Brkt Shoulder Bolt 437 Dia x 180 Lg Extension Spring 50 O D x 4 25 Lg Engine B amp S Wheel Ass y Comp 10 0 x 2 75 Sleeve 632 1 0 x 875 O D x 90 Lg Hex Wash Hd Self Tap Scr 1 4 20 x 50 Lg 1 2 V Pulley 7 8 1 0 x 7 8 1 0 x 3 1 4 O D V Belt 4L 1 2 V x 30 Lg Belt Cover L Wash 5 16 I D Hex Bolt 3 8 24 x 1 0 Lg 1 22. Oil Fill Cap 45 Male Adapter 7 16 20 MJ 1 4 18 NP O Ring 92 I D x 1 16 O D x 116 Dia Hex Bolt 3 4 x 4 0 Lg Hex Nut 11 16 12 Thd Hex Bolt 5 16 24 x 1 00 Lg Grade 5 Engagement Rod 16 75 Lg Fl Wash 344 I D x 62 O D x 063 Hair Pin Cotter 5 16 Dia faster service obtain standard nuts bolts and washers locally If these items cannot be obtained locally order by part number and size as shown on parts list Model 638 2 1 2 DIA CYLINDER PARTS LIST FOR MODEL 638 1 717 0816 2 753 0392 DESCRIPTION Cylinder Ass y Comp 2 1 2 Cyl Kit O Ring Set MTD PRODUCTS INC YARD MAN COMPANY BOX 36900 CLEVELAND OHIO 44136
3. Never place hands or feet between log and split 2 Wear proper head gear to keep hair away from ting wedge or between log and ram during moving parts Always wear protective hearing forward or reverse stroke To do so may result devices as needed in crushed or amputated fingers or toes or 3 Always wear safety shoes A dropped log can worse you may lose an arm or foot seriously injure your foot 4 straddle the splitter when using it A slip 7 Always wear safety glasses goggles while in any position could result in a serious injury operating your splitter A piece of splitting log 5 not step over your log splitter when the could fly off and hit your eyes engine is running You may trip or accidentally 5 lf you wear gloves be sure they are tight fitting activate the ram if your step over If you need without loose cuffs or draw strings to get to the other side walk around 6 Use your log splitter in daylight or under good 6 Never try to split two logs on top of each other One may fly out and injure you 10 11 12 13 14 16 17 18 When loading the log splitter place your hands on the side of the log not at the ends Never attempt to load your splitter while the ram is in motion You may get caught by the ram and injured Only use your hand to operate the ram or control lever Never use your foot or a rop or any other extension device This could resu t in your inability to stop your s
4. enclosure Always store gasoline in an approved tightly sealed container Store the container in a cool dry place Do not store in a building where ignition sources are present To reduce fire hazard keep engine free of grass leaves wood chips and excessive grease and oil The hydraulic system of your log splitter requires careful inspection along with the mechanical parts Be sure to replace frayed kinked or otherwise damaged hydraulic components Fluid escaping from a very small hole can be almost invisible Do not check for leaks with your hand Escaping fluid under pressure can have sufficient force to penetrate skin causing serious personal injury Leaks can be located by passing a piece of cardboard or wood over the suspected leak and looking for discoloration Should it become necessary to loosen or remove any hydraulic fitting or line be sure to relieve all pressure by shutting off the engine and moving the control handle back and forth several times Do not remove the cap from the hydraulic tank or reservoir while your log splitter is running Hot oil under pressure could cause injury The pressure relief valve on your splitter is pre set at the factory Do not adjust the valve Only a qualified service technician should perform this adjustment Completely drain fuel tank prior to storage This guards against accumulation of fuel fumes which could result in a fire hazard Never store log splitter outside withou
5. engagement handle Place rubber washer B on shoulder bolt Secure to bracket with lock washer C and hex nut D See figure 7 RUBBER WASHER B LOCK WASHER C HEX NUT D FIGURE 7 LEVER ON ENGAGEMENT PUMP HANDLE 10 Place the engagement handle in the notch in the slotted bracket Reverse position See figures 8 and 11 Thread the ferrule E onto the end of 49 SS engagement rod Wy 11 Push the lever on top of the pump as far toward V NOTCH the rear of the unit as it will go as shown in figure 8 Hold it in this position and adjust the ferrule on the engagement rod so the ferrule lines up with the hole in the engagement handle 12 Secure the ferrule to engagement handle with FERRULE E 2 flat washer G cotter F FIGURE 8 FUNNEL OPERATION BEFORE STARTING BREATHER 1 Fill reservoir tank on log splitter with approx imately 2 gallons of Dexron l automatic transmission fluid as follows Check fluid level 4 before each use Block front of log splitter so the beam is level B Remove the fluid check plug from the back of the log splitter See figure 9 If fluid starts to come out of the hole fluid level is correct If it does not replace the check plug loosely pull the cap off the breather tube and add Dexron automatic transmission fluid until fluid starts out of the hole when the plug is removed C Replace flui
6. may result in personal injury SAFE OPERATION PRACTICES FOR LOG SPLITTERS TRAINING 7 Never operate your splitter on slippery wet 1 Before operating this splitter read and under muddy or icy surfaces Safe footing is essen stand this manual completely Become familiar tial in preventing accidents Never operate your with it for your own safety To fail to do so may splitter while attached to a towing vehicle cause serious injury Do not allow anyone to 8 Only operate your splitter on level ground and operate your splitter who has not read this not on the side of a hill It could tip or rolling manual Keep this manual in a safe place for logs or poor footing could cause an accident future and regular reference and for ordering Operating the splitter on level ground also replacement parts prevents the spillage of gasoline from the fuel 2 use your splitter for any other purpose tank than splitting wood It is designed for this use 9 Never attempt to move the log splitter over and any other use may cause an injury Your log hilly or uneven terrain without a tow vehicle or splitter is a precision piece of power equipment adequate help not a playtoy Therefore exercise extreme 10 Always block the wheels to prevent movement caution at all times of log splitter while in operation 3 Never allow children to operate your log 11 Check the fuel before starting the engine splitter Do not allow adults to operate it without Gasoline i
7. operate your splitter in poor mechanical condition or when in need of repair Periodically check that all nuts bolts screws hose clamps and hydraulic fittings are tight to be sure equipment is in safe working condit on Where appropriate check all safety guards and shields to be sure they are in the prcper position Never operate your splitter with safe ty guards shields or other protective res removed These safety devices are for your protection Replace all damaged or worn parts such as hydraulic hoses and fittings immediately manufacturer approved replacement parts Do not change the engine governor setting or overspeed the engine This increases the hazard of personal injury The maximum engine sped is preset by the manufacturer and is within s 3fe ty limits 5 10 11 12 13 14 15 16 17 Do not alter your splitter in any manner such as attaching a rope or extension to the control lever or adding to the width or height of the wedge Such alterations may cause your split ter to be unsafe Perform all recommended maintenance pro cedures before you use your splitter Do not service or repair your log splitter without disconnecting the spark plug wire Never store the equipment with gasoline in the tank inside of a building where ignition sources are present such as hot water and space heaters clothes dryers and the like Allow the engine to cool before storing in any
8. 3 1 2 H P Model Numbers 247 638 000 LOG SPLITTER pire IMPORTANT Read Safety Rules and Instructions Carefully Thank you for purchasing an American built product FORM NO 770 5204B Safe Operation Practices Assembly Instructions Operation Maintenance This unit is equipped proved forest covered INDEX Saha SOROR IR RUE RR d 3 Off Season Storage np 5 Trouble Shooting Chart vates So ede e e S 7 Illustrated Parts NIMES 9 Repair Parts Lists Instructions with this symbol are for personal safety Be to follow them 4 Cx with an internal combustion engine and should not be used on or near any unim brush covered or grass covered land unless the engine s exhaust system is equipped with a spark arrester meeting applicable loca state laws if any If a spark arrester is used it should be maintained in effective working order by the operator In the State of California the above is required by law Section 4442 of the California Public Resources Code Other states may have similar laws F laws apply on federal lands A spark arrester muffler is available at your nearest engine authorized service center 2 s es s q 9 3 c 9 n on cxx artificial light x To reduce the potential for any injury comply with the following safety instructions Failure to comply with the instructions
9. AL V Pulley 5 8 I D x 3 1 2 O D Set Scr 1 4 28 x 25 Lg Bell Wash 40 1 0 x 88 O D Hex Wash Hd TT Tap Scr 3 8 16 x 87 Lg Hex Nut 5 16 24 Thd Hex Bolt 5 16 18 x 1 00 Lg L Wash 5 16 1 0 1 Axle Shaft 5 8 Dia x 25 5 Lg 741 0116 726 0214 781 0002 714 0133 712 0267 736 0119 727 0302 737 0183 737 0182 726 0132 737 0184 717 0803 714 0507 736 0264 727 0301 727 0300 726 0146 737 0191 712 0267 736 0119 736 0275 710 0442 710 0604 721 0205 781 0023 721 0203 712 0203 736 0364 781 0036 745 0174 737 0197 721 0204 710 0920 712 0338 710 0117 747 0493 736 0264 714 0104 PART COLOR CODE DESCRIPTION Flange Brg w Flats 631 1 0 Push Cap 5 8 Dia Rod Frame Engine Sq Key 3 16 x 3 16 x 1 50 Lg Hex Nut 5 16 18 Thd L Wash 5 16 I D High Pressure Hose Adapter or Boss to MJIC 9 16 18 to 7 16 20 Adapter 3 4 Tubing to 3 4 16 M Boss Hose Clamp 5 8 1 0 Adapter 1 2 Tube 9 16 18 or M Boss Valve Ass y Cotter Pin 3 32 Dia x 75 Lg FI Wash 344 I D x 62 O D x 063 Return Hose 50 1 0 Suction Hose 75 1 0 Hose Clamp 1 4 1 0 Adapter 1 0 Tube 1 1 16 12 O Ring Hex Nut 5 16 18 Thd L Wash 5 16 I D F1 Wash 343 1 0 x 687 O D x 062 Hex Bolt 5 16 18 x 1 50 9 Hex Tap Scr 5 16 Gasket End Plate Gasket Hex Nut 3 4 Thd L Wash 3 4 D Filler Tube Ass y
10. d check plug securely Replace cap on the breather tube Remove block from under front of beam DO log splitter with out proper amount of trans mission fluid in reservoir tank beam 2 Service engine with oil as instructed in the separate engine manual packed with your unit 3 Fill fuel tank using clean fresh regular grade automotive gasoline Fill tank completely Refer to engine manual packed with log splitter for complete instructions for the care and maintena 1ce of engine READ DIRECTIONS CAREFULLY 4 Bleed the air from the hydraulic system as follcws a Remove the breather cap b Start the engine c Slowly work the engagement handle forward and backward until the ram moves smoothly in both directions d Stop the engine Remove the fluid check p ug and check fluid level as specified in step Add fluid as necessary and bleed air from the hydraulic system until oil level is correct the ram operates smoothly e Replace breather cap securely NOTE Be certain to bleed the air from the hydraulic system as instructed above after any repair work is done on the pump valve or cylinder if a hose is removed for any reason or when adding fluid to the reservoir E 9 9 WARNING 4 Do not operate unit with the breather cap removed TO START ENGINE 1 Place throttle control lever on engine in CHC KE position towards the front of splitter See ficu
11. e as follows 1 Drain gasoline by tipping or by siphon hose the run engine until remainder is used tank carburetor are empty Drain gasoline into container outdoors away from fire or flame Be careful not to lose the square key on the crankshaft HEX BOLT 2 Drain carburetor by running engine until it stops from lack of fuel 2 3 Protect the inside of engine for storage removing spark plug and pouring one ounce of SAE 30 oil through spark plug hole into cylinder Crank engine without starting several times to spread oil over cylinder walls 4 Never store outside without a waterproof cover E gt wore When storing any type of power equip FIGURE 14 ment in an unventilated or metal storage shed care should be taken to rustproof the equipment Using a light oil or silicone coat the equipment 6 Loosen the three engine mounting bolts 19 especially the beam and all moving 1 2 wrench See figure 15 parts 10 ENGINE TROUBLE SHOOTING CHART SYMPTOM POSSIBLE CAUSE S SOLUTION Engine fails to start Check fuel tank for gas Fill tank if empty B Spark plug lead wire B Connect lead wire disconnected C Faulty spark plug C Clean adjust gap or replace See engine manual A 2 Hard starting or loss of Spark plug wire loose A Connect and tighten spark plug wire power B Dirty air cleaner B Clea
12. l log is split 6 Move the engagement handie to the rear to return ram The ram should take approximately 22 seconds to make complete cycle This speed may vary depending on throttle setting and temperature of hydraulic fluid If you lock the handle the reverse slot the ram will return until it hits the engagement bracket which will throw the engagement handle into neutral automatically 1 WARNING Never attempt to cut a log in half with the log splitter Never stand next to the ram when operating Always stand behind the ram MAINTENANCE Always stop engine disconnect spark plug wire before performing any maintenance or adjustments ENGINE OIL Change oil first two 2 hours of operation Check oil level every five 5 operating hours or each time equipment is used Change oil every twenty five 25 operating hours or sooner if equipment is operated in extremely dusty or dirty conditions Refer to engine manual for quantity and type of oil LOG SPLITTER RESERVOIR FLUID Check fluid level in log splitter reservoir before every 3e Refer to Before Starting under OPERATION section Change the hydraulic fluid in the reservoir every 100 hours of operation Remove the six hex bolts lock washers and hex nuts which hold the end plate to the beam Remove the plate and drain the fluid Be prepared to catch the fluid in a suitable contai
13. ls M 1 Axle Shaft N 1 Engagement Rod O 1 Engagement Handle FIGURE 2 AXLE PUSH CAP AXLE SHAFT vj 1 Remove log splitter and loose parts from carton Make certain all parts and literature have been removed from the carton before the carton is discarded 2 Using a raw hide or plastic hammer tap one axle push 1 one end of axle shaft See wa figure 3 3 Slide one wheel onto the axle shaft 4 Slide the axle through the frame from the right hand side of the splitter as viewed from standing FIGURE 3 behind it LEFT HAND SIDE OF SPLITTER 5 Slide spacer J onto axle shaft the left hand side of the splitter Spacer should be on the engine side of the splitter See figure 4 Place the other wheel on the axle SPACER J FIGURE 4 6 Secure wheel to axle with push 1 See figu I 5 PUSH CAP I FIGURE 5 _ gt ENGAGEMENT 7 Hook the bent end of the engagement rod N ROD N into the lever on top of the pump See figure 6 8 Next place one flat washer G over the rod Insert the cotter pin H into the hole in the rod and secure by bending the ends of the cotter in opposite directions FIGURE 6 ENGAGEMENT HANDLE 0 Place the flattened end of the engagement handle down through the slotted bracket beside the beam Place shoulder bolt A through the bottom hole in
14. n air cleaner as described in engine manual 3 Engine overheats A Carburetor not adjusted A Adjust carburetor See engine manual properly B flow restricted B Remove blower housing and clean as described in the engine manual Fill crankcase with the proper oil C Engine oil level low C A A Check and fill reservoir tank as instructed in Operation Section B Tighten belt or replace if worn See maintenance section C Adjust pump setting to 3 000 p s i Reservoir fluid level low 4 Will not split logs B is slipping C Leaking cylinder A Broken seals A Replace seals B Scored cylinder B Replace cylinder Pump setting incorrect OTE For repairs beyond minor adjustments please contact your local service dealer should be performed an authorized service dealer on v 11 Model 638 mb NOTE This instruction manual covers various models and all specifications shown do not necessari ly apply to your model Specifications subject to change without notice or obligation NOTE The engine is not under warranty by the log splitter manufacturer If repairs or service is needed on the engine please Yellow Pages C your telephone book under Engines Gasoline contact your nearest author ized engine service outlet Find It Fast Check the Yellow of in The 638 PART
15. nect the spark plug wire from the spark plug and ground against the engine block 2 Drain the gasoline from the fuel tank or place a piece of plastic under the cap to prevent leakage Tip the splitter on one side Remove four self tapping screws from the bottom belt cover and frame Refer to figure 13 5 Loosen the three engine mounting bolts using a 1 2 wrench Refer to figure 15 6 Slide the engine outward to tighten the belt until there is approximately 1 2 deflection Tighten engine mounting bolts securely BELT REPLACEMENT 1 Disconnect the spark plug wire from the spark plug and ground against the engine block 2 Drain the gasoline from the fuel tank or place a piece of plastic under the cap to prevent leakage 3 Tip the splitter on one side 4 Remove four self tapping screws from the bottom belt cover and frame See figure 13 MOUNTING 29 m BOLTS e SELF TAPFING SCREWS FIGURE 13 FIGURE 15 5 Using a 9 16 wrench remove the engine pulley 7 Install the new belt and replace the engine pulley by removing the hex bolt and lock washer See I 8 Slide the engine outward to tighten the new belt fi 14 Slip th ll ff 4 pullsy and until there is approximately 1 2 deflection Tighten engine mounting bolts securely OFF SEASON STORAGE BED Nore In event engine is to be stored for any length of time 30 days or more prepar
16. ner NOTE Drain the hydraulic fluid and flush the reservoir tank assembly and hoses each time repair work is performed in the tank hydraulic pump or valve Contaminants in the fluid will damage the hydraulic components END ING 12070 is HEX BOLTS LOCK WASHERS HEX NUTS INLET FIGURE 12 HOSE When the hydraulic fluid is drained from the reservoir clean the strainer tube assembly as follows 1 Remove the hose clamp at the inlet hose bottom hose See figure 12 2 Pull the inlet hose off the fitting at the beam Using an adjustable wrench remove the fitting from the beam 3 Reach inside the end of the beam and pull out the strainer tube assembly 4 Clean thestrainer tube assembly and reassemble in reverse order Reassemble the end plate Refill reservoir with ap proximately 2 gallons of Dexron li automatic transmission fluid and bleed the air from the hydraulic system as instructed in Before Starting under OPERATION section HOSE CLAMPS Check the hose clamps on the bottom of the pump for proper tightness before each use Hose clamps on the return hose should be checked once a season CARBURETOR ADJUSTMENTS cx If any adjustments are made to the engine while the engine is running e g carburetor keep clear of all moving parts Be careful of heated surfaces and muffler Refer to engine manual packed with your unit for carburetor adjustment information BELT ADJUSTMENT 1 Discon
17. plitter quickly eno ugh and cause an injury Always keep fingers away from any cracks that open in the log during splitting operation They can quickly close and pinch or amputate your fingers Never attempt to split wood across the grain Some types of wood may burst or fly out of your splitter and result in injury to you or a bystan der For logs that are not cut square the loncest portion of the log should be rotated down and the most square end placed against the Keep your work area clean Immediately remove split wood around your splitter so that you do not stumble over it Never move the log splitter while the engine is running Never leave your log splitter unattended with the engine running Shut off the engine if you are leaving your splitter even for a short period of time Someone could accidentally activate the ram and be injured Do not run engine in an enclosed area Exheust gases contain carbon monoxide This odorless gas can be deadly when inhaled Be careful not to touch the muffler after the engine has been running as it is HOT If the equipment should start to vibiate abnormally stop the engine and check im mediately for the cause Vibration is generally a warning of trouble When cleaning repairing or inspecting make certain all moving parts have stopped Disconnect the spark plug wire and keep the wire away from the plug to prevent accidental starting MAINTENANCE AND STORAGE 1 2 Do not
18. re 10 I Nore A warm engine may not require choking Simply place lever in RUN position A RUN or A THROTTLE CONTRCL LEVER 27 24 S gt J lt FIGURE 10 2 Grasp starter handle place one foot on wheel and pull starter handle with a quick full arm stroke Return rope slowly to the engine 3 After engine starts move throttle control lever to RUN position TO STOP ENGINE 1 Move throttle control lever to STOP position 2 Disconnect spark plug wire from spark plug to prevent accidental starting while equipment is unattended USING YOUR LOG SPLITTER Your log splitter is designed for safe efficient operation BE CAREFUL TO KEEP HANDS AND FEET AWAY FROM MOVING PARTS Engagement handle has three positions See figure 11 Forward ram moves toward wedge Neutral ram stops in place Reverse ram returns ENGAGEMENT HANDLE ENGAGEMENT HANDLE HELD IN FORWARD IN NEUTRAL POSITION 7 POSITION 4 i I l 1 I ENGAGEMENT HANDLE LOCKED IN REVERSE POSITION FIGURE 11 Maximum length that can be split is 20 TO OPERATE LOG SPLITTER 1 Set throttle at maximum speed 2 Place log on beam and hold in place with right hand 3 Slowly move engagement handle forward until ram rests against log Release engagement handle Neutral 4 Remove your hand from the log and step behind the ram 5 Move engagement handle forward unti
19. s an extremely flammable fuel Do not proper instruction Only persons well acquainted fill the gasoline tank indoors when the engine with these rules of safe operation should be is running or while the engine is still hot allowed to use your log splitter Replace gasoline cap securely and wipe off any 4 Only the operator is to be near your log splitter splilled gasoline before starting the engine as it during use Keep ali others including pets and may cause a fire or explosion children a minimum of 20 feet away from your 12 Both ends of each log must be cut as square work zone Flying wood can be hazardous If a as possible to help prevent the log from riding helper is assisting in loading logs never activate out of the splitter during operation the control until the helper is clear of the area OPERATION More accidents occur when more than one 1 Stand behind the ram when operating See person operates the log splitter than at any other illustrations time 5 Noone should operate this unit while intoxicated or while taking medication that impairs the senses or reactions A clear mind is essential for safety Never allow a person who is tired or otherwise not alert to use your splitter PREPARATION 1 Never wear loose clothing or jewelry that can be caught by moving parts of your log splitter 2 Know how to stop the unit and disengage the and pull you into it Keep clothing away from all controls moving parts of your log splitter 3
20. t a water proof cover Rain will cause rust on the inside of the cylinder TOWING 1 This unit should not be towed street highway or public road Any licensing needed to comply with the existing federal local or state vehicle requirements is the sole responsibility of the purchaser Before towing certain the log splitter is correctly and securely attached to the towing vehicle and the safety chains if so equipped or where required by state law are in place Leave slack in chains for turning allowance Do not allow anyone to sit or ride on your splitter They can easily fall off and be serious ly injured vo ASSEMBLY INSTRUCTIONS This unit is shipped WITHOUT GASOLINE OIL After assembly see separate engine manual for proper fuel and engine oil recommendations TOOLS REOUIRED 1 Raw Hide or Plastic Hammer 1 3 4 Wrench 1 Adjustable Wrench 1 Pair of Pliers OTHER MATERIALS NEEDED Approximately 2 gallons of Dexron ll automatic transmission fluid may be obtained at any local service auto parts store Funnel Engine oil and gasoline refer to separate engine manual CONTENTS OF HARDWARE See figure 1 1 Shoulder Bolt 1 Rubber Washer 1 Lock Washer 1 Hex Nut 1 Ferrule 1 Hairpin Cotter 2 Flat Washers 1 Cotter Pin 2 Axle Push Caps 1 Spacer gt LOOSE PARTS IN CARTON See figure 2 L 2 Whee
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