Little Wonder 8271 User's Manual
Contents
1. Figure 5 G Attaching the Chain Loop Assembly to the Boom Arm Assembly Figure 6 1 Slip the threaded end of the Chain Loop Assembly 720290 through the hole found at the end of the Boom Arm Assembly 720285 17 Once through secure the Chain Loop Assembly with the Nut 64229 05 The level position of the Hose Assembly to the Inlet Flange Assembly can be controlled by adjusting the position of the Nut on the thread of the Chain Loop Assembly NUT 720576 BOOM ARM ASSEMBLY CHAIN LOOP NUT 720585 BOLT 720588 AES l Adding Oil to the Engine 1 Fill the crankcase with the proper oil to the F mark found on the dipstick The oil recommendations are found in the Engine Oil and Fuel section of this manual J Filling the Gas Tank 1 Fill the tank with the proper fuel Take extra caution when filling the tank not to over fill it The fuel recommendations are found in the Engine Oil and Fuel section of this manual H Attaching the Hose Band to the Chain Loop Assembly Figure 6 1 After wrapping the Hose Band around the Hose insert the Bolt 64123 61 through the holes in the Hose Band Once through secure the Bolt in the Hose Band with the Nut 64229 02 Attach the Hose Band to the Chain Loop Assembly by connecting the chain to the Bolt 64123 61 via the supplied Carabiner Quick Clip 720487 Make sure the Hose Band is in the proper position with respect to the Hose to2. ASSEMBLY 54 48228 3A CLIP WIRE HARNESS 55 720377 17 12 INLET FLAPPER 55 720378 17 14 INLET FLAPPER 56 720265 17 PAINTED BOOM ARM ASSEMBLY 57 720289 1 1 2 x 1 4 WALL SQUARE TUBE PLUG 58 720428 1 THRUST WASHER 59 720580 1 8 GRADE G LOCK FLANGE NUT 60 720290 CHAIN LOOP ASSEMBLY 61 64229 05 1 2 13 NYLON INSERT NUT 62 720487 CARABINER QUICK CLIP 63 720291 17 12 HOSE BAND 63 720292 17 14 HOSE BAND 64 64123 61 5 16 18 x 1 3 4 LG GRADE 8 BOLT 65 721200 DISCHARGE CHUTE WITHOUT LINER 66 720262 17 DISCHARGE CLAMP RING 67 64229 03 3 8 16 NYLON INSERT NUT YELLOW ZINC 68 38524 3 8 16 FEMALE THREADED KNOB 69 720381 17 12 HOSE FLANGE ASSEMBLY 69 720262 17 14 HOSE FLANGE ASSEMBLY 70 720485 12 DIA x 10 LG INTAKE HOSE 70 720486 14 DIA X 10 LG INTAKE HOSE 71 720264 12 PLASTIC INTAKE NOZZLE 71 720265 14 PLASTIC INTAKE NOZZLE 72 720266 17 12 PLASTIC INTAKE NOZZLE HANDLE 72 720267 17 14 PLASTIC INTAKE NOZZLE HANDLE 73 720390 HOSE CLAMP LEFT HANDED 74 64262 020 3 6 16 x 2 3 4 LG GR 5 HEX BOLT 75 720436 HOSE 6 X 12 1 4 DIAMETER 76 720388 12 HOSE CLAMP RIGHT HANDED T7 720488 HOUSING GUARD LINER 78 79 721202 CHUTE LINER WITH STUDS 80 721201 DISCHARGE CHUTE WITH LINER 81 720489 SEAL DISCHARGE 3 18 2 YEAR LIMITED SERVI
3. LG GR 5 HEX BOLT 64255 01 INSERT RIVNUT 5 16 8 720416 RUBBER LINER 720592 5 16 16 x 1 LG GR 5 HEX BOLT 64163 55 5 16 SAE GRADE 8 FLAT WASHER 64229 02 5 16 18 NYLON INSERT NUT 720462 10 PAINTED TRANSITION DISCHARGE TUBE 64018 9 5 16 18 x 3 4 LG SQ NECK CARRIAGE BOLT 720437 LINCH PIN w LAYNARD 64163 29 11 32 1 D 1 1 4 O D WASHER 64268 02 5 16 18 GRADE G LOCK FLANGE NUT 720440 FAN HUB SPACER 720470 22HP BALANCED FAN ASSEMBLY 720472 27HP BALANCED FAN ASSEMBLY 720362 TALON RING ASSEMBLY 64123 160 5 8 18 x 3 LG GR 8 HEAVY HEX CAP SCREW 720364 10 12 INLET ASSEMBLY 720368 10 14 INLET ASSEMBLY 5 16 18 WIZ NUT COIN ID gt 7h PB 1 IAIN gt fale aja fa gt 720373 17 12 HOSE FLANGE RETAINER PLATE 720374 17 14 HOSE FLANGE RETAINER PLATE 720509 5 16 WASHER Model 8221 amp 8271 Part Numbers BALLOON ITEM _ PART DESCRIPTION 8221 QTY 8271 QTY 49 720258 10 FLAPPER RETAINER 50 154 5 16 18 FEMALE THREADED KNOB 51 720234 17 PAINTED SWITCH PLATE 52 90 0532 5 16 18 x 4 LG GRADE 8 BOLT 53 720482 SAFETY SWITCH WIRE
4. OTHER REPRODUCTIVE HARM Safety and Warnings A Safety Decals In order to keep operators of the Shredding TruckLoader informed regarding safety and or unit operation decals labels have been placed on various parts of the unit Adherence to the warnings and instructions depicted or otherwise conveyed in these decals is absolutely essential to the safe operation of the Shredding TruckLoader These decals labels must be replaced if they become illegible due to abrasion etc It is your responsibility to replace the decals labels when they become hard to read The location of these decals and their part numbers for ordering are shown on the picture below A WARNING A DANGER IMPROPER USE OR CARE OF THIS SHREDDING TRUCKLOADER OR FAILURE TO WEAR PROPER PROTECTION CAN RESULT IN SERIOUS INJURY READ AND UNDERSTAND THE RULES FOR SAFE OPERATION AND ALL INSTRUCTIONS IN THIS MANUAL WEAR HEARING EYE AND BREATHING PROTECTION 2y DID EEDS 720600 Caution Hot Surface WARNING WARNING yan P N 720609 Caution Thrown objects Keep bystanders away KEEP HANDS and FEET AWAY Caution Thrown objects Keep bystanders lt away Always wear eye ear and breathing protection P N 600602 Warning Label AWEIGHT LIMIT 500 LBS DO NOT USE OR SERVICE THE UNIT WHEN IT IS SUSPENDED FROM THE LIFTING LUG Keep hands and feet away fr
5. Wonder Shredding TruckLoader This professional debris handling machine was designed to the highest standards to ensure many hours of uninterrupted service This manual provides the information necessary for safe and efficient operation and service For your safety it is critically important that you read and understand this entire manual before operating your Shredding TruckLoader Specifications Model Dry Weight Max Rpm 8221 500 Ibs 3600 8271 500 Ibs 3600 B Service Information Shredding TruckLoader Unit Contact your local Little Wonder dealer Engine Contact an authorized Kohler dealer Dealers are listed in the Yellow Pages under Lawn and Garden Equipment Supplies Lawn Maintenance or Lawn Mowers Your dealer will need to know the model and serial number of your engine For their location please consult the owner s manual provided with your engine C Special Safety Information WARNING DANGER ATTENTION THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHEN YOU SEE THIS SYMBOL HEED ITS WARNING STAY ALERT WARNING DANGER TO REDUCE THE POTENTIAL FOR ACCIDENTS COMPLY WITH THE SAFETY INSTRUCTIONS IN THIS MANUAL FAILURE TO COMPLY MAY RESULT IN SERIOUS PERSONAL INJURY AND OR EQUIPMENT AND PROPERTY DAMAGE WARNING DANGER THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR
6. allow free movement with the Boom Arm Assembly Figure 6 K Connecting the Battery 1 Connect the Red Battery Cable 720339 found connected to the engine starter to the positive terminal of the battery with the Bolt 64123 114 and Nut 64268 01 provided Connect the Black Battery Cable 720340 found connected to the engine block to the negative terminal of the battery with the Bolt 64123 114 and Nut 64268 01 provided L Discharge Extension Kit Assembly Instructions Contents Included in Kit 1 Discharge Extension Hose 720436 2 Hose Clamp 720388 Tools Needed 1 9 16 Box Wrench or Socket Wrench w 9 16 Socket 2 Socket Wrench w 3 8 Socket or Flat Head Screw Driver 3 Utility Knife if required 4 Heavy Duty Wire Cutters if required Disassembly and Assembly Instructions 1 Turn off the TruckLoader and disconnect both of the spark plug wires from the engine 2 Disassemble the TruckLoader Discharge Flapper by removing the knob 2 nuts 2 washers and 3 bolts 3 Remove the Discharge Flapper from the Discharge Nozzle 4 Slide the Discharge Extension Hose over the end of the Discharge Nozzle where the Flapper has been removed Make sure the Hose has overlapped the Discharge Nozzle by at least 6 inches 5 Secure the attachment of the Discharge Extension Hose to the Discharge Nozzle with the supplied Hose Clamp When installing the Hose Clamp make sure it is positi
7. was being operated make sure the engine has been turned off and is allowed to cool off completely 2 Once you have determined the engine is cool fill the tank with the proper fuel Take extra caution when filling the tank not to over fill it The fuel recommendations are found in the Engine Oil and Fuel section of this manual Transportation A Preparing the TruckLoader Unit for Transportation 1 Make sure the engine is off 2 Disconnect the Carabiner 720487 from the hose band 3 Attach the Carabiner to the chain link closest to the Boom Arm Assembly 4 Rotate the Boom Arm Assembly toward the vehicle to allow the locking bosses on the Arm and Column to line up Once the bosses are aligned insert the Linch Pin 720437 through the hole and snap the ring over the boss to secure 10 Make sure the Chain Loop Assembly cannot make contact with anything other than the Boom Arm Assembly If necessary use a bungee cord to secure it Remove the Hose Assembly from the Inlet Flange Assembly Close the Inlet Flapper and rotate the Flapper Retainer 720257 to allow the Flapper to be secured by tightening the knob Remove the Discharge Nozzle from the TruckLoader Housing Secure all the removed TruckLoader parts in the bed of the vehicle with the proper rope or hardware Before moving a trailer containing the TruckLoader unit be sure that everything is properly secured for road travel and that safety towing chains ar
8. CE amp WARRANTY POLICY FOR GASOLINE POWERED FOR SHREDDING TRUCKLOADER The LITTLE WONDER Shredding TruckLoader is guaranteed against defects in material and workmanship for a period of TWO YEARS from date of purchase when used for RESIDENTIAL SERVICE or COMMERCIAL SERVICE Any LITTLE WONDER Shredding TruckLoader or part found to be defective within the warranty period is to be returned to any registered LITTLE WONDER Dealer Engines for all gasoline powered products are warranted separately by the engine manufacturer Therefore there are no warranties made expressed or implied for engines for gasoline powered products by LITTLE WONDER Transportation charges for parts and units submitted for replacement under this warranty must be borne by the purchaser THIS WARRANTY shall not be effective if the product has been subject to misuse negligence or accident or if the product has been repaired or altered outside of our Southampton factory or authorized repair facility in any respect which affects its condition or operation LITTLE WONDER shall not be liable for any special indirect or consequential damages arising from defective equipment Any implied warranty including merchantability of fitness for a particular purpose shall not extend beyond the written warranty period THIS WARRANTY shall only be effective if the enclosed Warranty Registration card is properly filled out and returned to LITTLE WONDER Div of Schiller Grounds Care
9. Inc at time of purchase WARNING DANGER THE ENGINE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER BIRTH DEFECTS OR OTHER REPRODUCTIVE HARM LITTLE WONDER DIVISION OF SCHILLER GROUNDS CARE INC 1028 STREET ROAD P O BOX 38 SOUTHAMPTON PA 18966 PHONE 877 596 6337 FAX 215 357 8045 877 LWONDER www littlewonder com P N 41632694 09 Specifications descriptions and illustrative material in this literature are as accurate as known at the time of publication but are subject to change without notice
10. LITTLE WONDER Shredding TruckLoaqer Models 8221 and 8271 N Table of Contents Important Information MOGUCOM naca 1 Service 88 0 4455549455 1 Special Safety Information 5 5 9 55 4 5 1 Safety and Warnings Safety Decals 2 General Safety Rules Warnings 30 5 4455594595 3 Warnings 0 57 5 55 4554595945 3 4 Engine Fuel Warnings 0 4 Engine Fuel Warnings 0 5 4 Assembly Instructions Hose AssemDl y 4 5 4959995688 5 Mounting Shredding TruckLoader Frame 5 Mounting Boom Arm to Housing Boom Column 6 Mounting Discharge Chute to TruckLoader POSNI feces dae sn neste 6 Changing Direction of Discharge 16 f Attaching Hose Assembly to Inlet 6 7 Attaching Chain Loop Assembly to Boom Arm ASSEIMDIY EEEn ONANAN 8 Attaching Hose Band to Chain Loop Assembly 8 Adding Oil to Engine secin 8 Filing Gas TANK ernn 8 Conn
11. RIALS FROM INTAKE OR DISCHARGE WHEN used AVARNING A DANGE UNIT IS RUNNING OR FAN IS ROTATING DO NOT SMOKE WHEN FILLING FUEL TANK A WARNING A DANGER A 12 DO NOT OPERATE UNIT IF EXCESSIVE VIBRATION OCCURS SHUT ENGINE OFF IMMEDIATELY REMOVE Don t leave the engine running while the Shredding SPARK PLUG WIRES AND CHECK FOR DAMAGED TruckLoader is unattended IMPELLER LOOSE IMPELLER BOLT LOOSE IMPELLER Don t store spill or use gasoline near flames or spark KEY OR LODGED FOREIGN OBJECTS B A Warnings Do s Always dress properly Do not wear loose clothing or jewelry They can be caught in moving parts Use of sturdy gloves non skid footwear and safety glasses are recommended Always wear ear protectors where possible Use respirator mask to 15 If the Shredding TruckLoader is mounted on a trailer make avoid breathing dust sure that the driver of the towing vehicle has the operator of the Shredding TruckLoader in full view at all times 13 Keep hands away from hose inlet and discharge chute 14 Disconnect spark plugs before doing any cleaning or maintenance There are two spark plugs on the machine Disconnect both Always stay alert Watch what you are doing and use common sense Do not operate Shredding TruckLoader when fatigued 16 When operating the Shredding TruckLoader operator must stay to the side of the machine never in front or behind Always keep hands away from air intake a
12. and debris out of the engine Remove the plug and check its condition Replace the plug if worn or reuse is questionable NOTE Do not clean the spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage Check the gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode Reinstall the spark plug into the cylinder head Torque the spark plug to 24 4 29J N m 18 22 ft Ib 4 Reinstall the spark plug into the cylinder head Torque the spark plug to 24 4 29J N m 18 22 ft Ib Electrode 14 Storage A Preparing for Long Term Two Months or More Storage 1 Clean the exterior surfaces of the unit including engine Change the Oil and Filter while the engine is still warm The fuel system must be completely emptied or the gasoline must be treated with a stabilizer to prevent deterioration To empty the fuel system drain the fuel tank and carburetor or run the engine until the tank and system are empty Drained fuel may only be stored for 30 days If a stabilizer is chosen follow the manufacturer s recommendation by adding the correct amount of additive for the amount of fuel to be stored Fill the tank with this clean fresh gasoline and run the engine for 2 to 3 minutes to get the stabilized fuel into the carburetor Intake Hose and Discharge View Remove the spar
13. area around the oil filter to keep dirt and debris out of the engine Remove the old filter Wipe off the surface where the oil filter mounts d Place a new replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material e Puta drop of oil on your fingertip and wipe it on the rubber gasket f Install the replacement oil filter to the filter adapter or oil cooler Turn the oil filter clockwise until the rubber gasket contacts the filter adapter or oil cooler then tighten the filter an additional 2 3 to 1 turn g Follow steps 4 5 from above Change Oil section Start the engine and check for oil leaks Correct any leaks before placing the engine into service Check oil level to be sure it is up to but not over the F mark D Heavy Duty Air Cleaner 1 Every 250 hours of operation more often under extremely dusty or dirty conditions replace the main paper element and check inner element Follow these steps a Unhook the two retaining clips and remove the end cap from the air cleaner housing b Pull the air cleaner element out of the housing See Removing Elements Figure E Spark Plug 1 Every 200 hours of operation remove the spark plugs check condition and reset the gap or replace with new plugs as necessa
14. blades to align with the notches provided in the Housing face Thread a 3 4 16 x 5 long grade 5 or better bolt into the hub to jack or push the Fan from the crankshaft of the engine The Little Wonder 910505 jacking screw is recommended Take note of the orientation of the fan with respect to the keyway upon removal This is important when reinstalling the Fan Upon removal of the Fan and Talon Ring inspect for damaged or worn blades If the Fan or Talon Ring is found to be damaged or excessively worn it should be replaced with a new part CHAMFERED LINER RUBBER HARDWARE LINER REMOVE NUTS TO DETACH 10 11 12 13 FAN ASSEMBLY TALON RING ALIGN FAN BLADE WITH HOUSING NOTCH FOR FAN INSTALLATION AND REMOVAL BOLT 720572 Reinstall the Fan onto the crankshaft and orient it to the same position as removed in Step 6 Once the Fan is aligned properly with the keyways of the Fan hub and engine crankshaft in line slide the Fan completely onto the crankshaft To reinstall the Talon Ring align the D hole in the ring with the mating shape found on the Fan hub Using a new fan bolt 64123 160 and adding a dab of Loctite 242 to it s threads complete the installation of the Fan and Talon ring by securing the bolt with the proper torque into the engine crankshaft Install the Inlet Assembly to the face of the Housing and secure with the previously removed hardware Connect the spa
15. choke control lever to the choke position 5 Move the throttle control lever to the middle position 6 Turn the ignition key clockwise to start the engine As soon as the engine starts release the key 7 After letting the engine warm up slowly move the choke lever to the open run position 8 See the engine manual for additional information on starting B Vacuuming 1 This machine has been designed for two methods of vacuuming debris e With the handles of the Intake Nozzle in the operator s hands move the Nozzle back and forth in a sweeping motion over the debris e Rotate the Hose Assembly 90 degrees at the Inlet to allow the Intake Nozzle to lay sideways on the ground By placing the Nozzle in this position debris can be raked into the Nozzle by the operator 2 While large amounts of debris can be vacuumed quickly with this machine caution must be taken to avoid blocking the airflow into the Nozzle 3 To increase the life of your Hose periodically rotate the Intake Nozzle with respect to the Hose This will allow the hose to wear more evenly C Stopping the Engine 1 Move the throttle control lever to the turtle slow position 2 Turn the key to the off position D Debris Blockage 1 If a decrease in suction is experienced there may be a debris blockage in the hose To remove this blockage simply grab the handles of the Intake Nozzle and stretch the hose out into a straig
16. contact with and inhalation of harmful fluids gases Turn off engine to make changeover Batteries produce explosive mists fumes and dust Be sure throttle is in the slow position 2 818 irte a ignition key is in the off position and 7 Check operation of the safety interlock switch daily Do not F open flames and other sources of a the Shredding TruckLoader has come ignition away from the battery at all defeat interlock system it is for your protection times Keep batteries out of the to a complete stop Remove the spark reach of chitdren Remove all 8 Do not allow children to operate machine plug wires from the spark plug before when servicing battones removing material Before disconnecting the negative 9 Do not override or remove any safety devices Oe cca Go nak r at the ground cable Don t point the Shredding TruckLoader terminal which could cause on A WARNING A DANGER A discharge chute in the direction of explosion if hydrogen gas or gasoline vapors are present people cars glass or anything that could be injured or damaged by blown debris 10 FAN COASTS AFTER THE ENGINE IS TURNED OFF Don t attempt to repair Shredding TruckLoader Have repairs made A HERNING A DANGEE A by a qualified Little Wonder dealer or repairman See that only Little 11 ROTATING FAN DON T ATTEMPT TO REMOVE Wonder and recommended engine manufacturer replacement parts are MATE
17. cooling areas for debris and clean as necessary Check the operation of the safety switch Check for excessive vibration loose or damaged parts on the unit Inspect and clean the Hose and Discharge Nozzle of clogging debris Inspect the condition of all warning labels and replace if necessary Inspect for excessive vibration loose or damaged parts on the unit Valet the engine oil level and fill if needed to the proper eve Change the engine oil as instructed in this manual Remove the cooling shrouds of the engine and clean the cooling areas of dust dirt or debris Change the engine oil filter as instructed in this manual Check the engine spark plugs condition and gap Service the engine s Heavy Duty Air Cleaner including replacing the Main Element as instructed in this manual Service the engine s Heavy Duty Air Cleaner including replacing the Inner Element as instructed in this manual See the Kohler Engine Owner s Manual for additional required maintenance Maintenance A Removing and Replacing the Fan and Talon Ring Figure 7 1 EDGE OF LINER Disconnect the spark plug wires from the spark plugs on the engine Disconnect safety switch wire from engine Unbolt and Remove the Inlet Assembly from the face of the Housing Remove the bolt 64123 160 securing the Fan and Talon Ring to the crankshaft of the engine Pull the Talon Ring off the face of the Fan hub Rotate the Fan to allow the
18. d the Nuts 64229 03 with a 1 2 wrench Rotate the Discharge Chute to the desired position Retighten the Knobs by hand and the Nuts if loosened with the 1 2 wrench F Attaching the Hose Assembly to the Inlet Assembly Figure 5 1 FLAPPER Loosen the knob and rotate the Flapper Retainer 720258 10 to allow the Inlet Flapper to be lifted upward With the Inlet Flapper held upward install the Hose Assembly by inserting the flange of the Hose Flange Assembly into the space gap between the face of the Inlet Assembly Flange and the back face Flange Retainer Plate as shown The pin located in the upper right corner of the Inlet Assembly Flange will prevent the Hose Flange Assembly from sliding out of this pocket INLET HOSE ASSEMBLY FLANGE KNOB RETAINER PLATE Since the Hose Assembly may be rotated 360 degrees orient the Intake Nozzle to your preferred position and lock it in place To lock the Hose Assembly in place tighten the two knobs attached to the Flange Retainer Plate and Flapper Retainer as shown By tightening the knobs it will push the flange of the Hose Flange Assembly against the flange of the Inlet Assembly and activate the Safety Switch Plate 720234 17 THIS MUST BE DONE TO OPERATE THIS UNIT When the Hose assembly is removed from the Inlet Assembly for unit transportation the Inlet Flapper must be closed and the Flapper Retainer 720258 10 must be rotated to lock it in place
19. e properly attached to the vehicle Engine Oil and Fuel A Oil Recommendations using the proper type and weight of oil in the crankcase is extremely important It is also important to check oil daily and change oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure 1 Oil Type Use high quality detergent oil of API American Petroleum Institute service class SC SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 40 Synthetic oils will provide better starting in extreme cold below 10 F NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade B Fuel Recommendations 1 Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended and must not be used on models where exhaust emissions are regulated 10 Gasoline Alcoho
20. ecting 88062 dened 8 Discharge Extension 0 5 5 5 9 Operation Starting the Engine 5 9 1 6 E E 60 5 9 Stopping the ENGine 555 5555545555594555 59555 559 9 Debris Blockage ucts ecient doe 9 Re filling the Gas 8 5 9 55 995 10 Transportation Preparing TruckLoader Unit for Transportation 10 Engine Oil and Fuel Oil and Fuel Recommendations Warnings 10 Maintenance Maintenance 56 60 1 6 55 5 4 55 59 955 11 Removing and Replacing Fan and Talon Ring 12 Liner Replacement 555 55555 13 Oil and Filter Change 9555 9955 9 13 Heavy Duty Air Cleaner ceceeeceeeeeeeeeeeeneeeetteeeeens 14 SPAK PIUQS oiai he 14 Storage Preparing for Long Term Storage 15 Exploded Assembly Views and Part Numbers Intake Hose and Discharge 15 Base Unit View 16 Part NUMDETS suisses nannaa 17 Warranties Warranty T Back cover Important Information A Introduction On behalf of everyone at Little Wonder we would like to thank you for your purchase of a Little
21. her 720428 onto the shaft of the Boom Column Assembly BOOM ARM ASSEMBLY D Mounting the Discharge Chute to the TruckLoader Housing Figure 4 1 Slide the Discharge Clamp Ring 720262 17 over the Discharge Chute and down onto its flange Lift the Discharge Chute s flange 720200 with the Discharge Clamp Ring 720262 17 and place on top of the Transition Discharge Tube s flange 720461 as shown Align the mounting holes of the Discharge Clamp Ring 720262 17 with the bolts on the Transition Discharge Tube s flange 720462 10 Secure the Discharge Clamp Ring 720262 17 to the Transition Discharge Tube s flange 720462 10 by lightly fastening a Nut 64229 03 and Knob 38524 in an alternating pattern as three of each are provided Position the Discharge Chute into the receiver box of the transport vehicle and tighten down the Nuts and 5 Secure the Boom Arm Assembly and Washers to the shaft with a Lock Nut 720580 6 As needed insert some 2 lithium based grease through the grease fitting provided in the Boom Arm Assembly 7 Install Linch Pin 720437 as shown BOOM COLUMN LOCK NUT THRUST WASHER GREASE FITTING LINCH PIN Figure 3 THRUST WASHER ROTATE TO DESIRED POSITION DISCHARGE DISCHARGE CHUTE CLAMP RING KNOB Knobs previously installed E Changing the direction of the Discharge Chute Figure 4 1 Loosen the Knobs 38524 by hand and if neede
22. ht line with respect to the Inlet of the unit while the engine is at full throttle 2 In the event the suction of the hose remains decreased after completing step 1 there may be a blockage in the housing In order to inspect the unit for blockages complete the following steps a Turn off the engine and wait until all moving parts have come to a complete stop b Disconnect the spark plug wires from the spark plugs on the engine c Remove the Hose Assembly from the Inlet Flange Assembly With this removed open the Inlet Flapper and remove any debris that is clogging the housing CAUTION SHOULD BE USED WHEN CLEARING DEBRIS FROM INSIDE THE HOUSING GLOVES SHOULD BE WORN AS SHARP EDGES ON THE FAN THE TALON RING OR IN THE DEBRIS MAY BE PRESENT d Remove the Discharge Chute from the Transition Discharge Tube s flange With the Chute removed inspect the Transition Discharge part of the housing and remove any debris clogging this area CAUTION SHOULD BE USED WHEN CLEARING DEBRIS FROM INSIDE THE HOUSING GLOVES SHOULD BE WORN AS SHARP EDGES ON THE FAN THE TALON RING OR IN THE DEBRIS MAY BE PRESENT e Inspect the Discharge Chute for debris and remove any debris clogging this area f In order to re assemble the removed parts please refer to the Assembly Instructions found in this manual After the unit is re assembled reconnect the spark plug wires and resume operation E Re filling the Gas Tank 1 If the unit
23. k plugs and add one tablespoon of engine oil into each spark plug hole Install plugs and ground spark plug leads do not connect the leads to the plugs Crank the engine two or three revolutions Store the unit and all of it s components in a clean dry well ventilated non child accessible sheltered area that is out of sun light and high ambient temperatures Base Unit View Model 8221 amp 8271 Part Numbers BALLOON ITEM _ PART DESCRIPTION 8221 QTY 8271 QTY 1 720903 22 HP KOHLER ENGINE 1 720904 27 HP KOHLER ENGINE 720483 OIL DRAIN VALVE 64163 34 3 8 SQ x 3 LG KEY 720451 17 PAINTED SKID FRAME 64123 234 3 4 10 x 4 LG HEAVY HEX CAP SCREW 64268 07 3 4 10 GRADE G LOCK FLANGE NUT 720279 1 1 4 ROUND TUBE PLUG 64123 82 WASHER FLAT 406 X 1 411 X 9GA 64213 31 3 8 SAE FLAT WASHER 64141 4 3 8 16 WIZ NUT 720491 GAS TANK 64123 75 3 8 x 1 3 4 LG GR 8 HEX BOLT 64163 87 3 8 SAE GRADE 8 FLAT WASHER 64229 03 3 8 16 NYLON INSERT NUT 720296 GAS TANK FUEL CAP 720490 007 GAS TANK OUTLET FITTING 4162977 5 FUEL LINE HOSE 13 021 KOHLER FUEL FILTER 4162977 015 30 FUEL LINE HOSE 88042N FUEL LINE HOSE CLAMP 108055 HEAVY DUTY 12V BATTERY 720465 BATTERY HOLD DOWN 720469 BLACK BATTERY CABLE 720468 RED BATTERY CABLE 64123 114 1 4 20 x 1 LG HEAVY HEX CAP SCREW 64268 01 1 4 20 LOCK FLANGE NUT 910503 BOLT SERRATED FLANGE 5 16 24 x 3 4 LG LOCKING PATCH 720460 10 PAINTED HOUSING ASSEMBLY 64139 18 3 8 16 x 1 1 4
24. l blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Maintenance Schedule 11 Daily or Before Starting the Engine Every 5 hours of Usage Every 100 hours of Usage Every 200 hours of Usage Every 250 hours of Usage Every 500 hours of Usage 2 Fuel Warnings Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings a way from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent a To minimize gum deposits in fuel system and to insure easy starting do not use gasoline left over from the previous season b Do not add oil to the gasoline c Do not overfill the fuel tank d Filler neck should not contain fuel Fill the fuel tank Check the engine oil level and fill if needed to the proper level Check the air cleaner for dirty loose or damaged parts Check the air intake and
25. mpurities Make sure the engine is level when filling checking and changing the oil Change the oil as follows a To keep dirt debris etc out of the engine clean the area around the oil fill cap dipstick and drain valve before moving to the next step b Attach a 1 2 I D hose to the fitting on the oil drain valve Place the other end of the hose in an oil pan Next remove the oil fill cap and dipstick then open the oil drain valve counter clockwise to begin drainage Be sure to allow ample time for complete drainage c Once all the oil has drained close the valve clockwise and remove the hose d Fill the crankcase with new oil of the proper type to the F mark on the dipstick Refer to Oil Type on page 11 Always check the level with the dipstick before adding more oil e Reinstall the oil fill cap and tighten securely Reinstall the dipstick NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or over the F mark on the dipstick Oil Filter Change Replace the oil filter at least every other oil change every 200 hours of operation Always use a genuine Kohler oil filter Part No 12 050 OI S Replace the oil filter as follows a Follow steps A to C from the above Change Oil section b Allow the oil filter to drain c Before removing the oil filter clean the
26. muffler and cooling fins Don t touch hot mufflers cylinders or cooling fins as contact may cause serious burns D Engine Fuel Warnings Do s Always use fresh gasoline Always handle fuel with care it is highly flammable Never add fuel to a machine with a running or hot engine Do not inhale fuel fumes as they are toxic The use of spark arrestor mufflers is required by law in the state of California Section 4442 of the California Public Resources Code as well as in other states or municipalities Federal laws apply on federal lands WARNING DANGER HANDLE FUEL WITH CARE IT IS HIGHLY FLAMMABLE FUELING A HOT ENGINE OR NEAR AN IGNITION SOURCE CAN CAUSE A FIRE AND RESULT IN SERIOUS PERSONAL INJURY AND OR PROPERTY DAMAGE Assembly Instructions A Hose Assembly Figure 1 1 2 Remove the Hose from the box With the assistance of a second person hold the hose at both ends and stretch it out as far as possible This will maximize the hose length and open the internal diameter Insert the Hose Flange Assembly into one of the open ends as shown Using one of the Hose Clamps secure the hose to the Hose Flange Assembly by wrapping the clamp around the hose portion covering the Hose Flange and tighten HOSE INTAKE NOZZLE HANDLE INTAKE NOZZLE NUT B Mounting the Shredding TruckLoader Frame Figure 2 1 There are four holes in the TruckLoader frame deck thr
27. nd air discharge chute 17 Wear gloves to protect your hands Always maintain and examine Shredding TruckLoader with care Follow maintenance instructions given in unit and engine manuals 18 Beware that the machine is loud and during normal operation it may interfere with speech communication 19 Check mounting hardware daily Beware of the possibility that the machine may overturn fall or tip over because of unexpected movement of the vehicle CAUTION ki Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock B Warnings Do s Con t Always store Shredding TruckLoader indoors When not in use store Shredding TruckLoader indoors in a sheltered area a dry place where it is not accessible to children The Shredding TruckLoader as well as fuel should not be stored in a house Keep throttle in the slow position and ignition key in the off position Always be sure Shredding TruckLoader is fully assembled Never operate Shredding TruckLoader without all guards and deflectors in place Ensure that all nuts bolts and screws are installed and properly tightened Always keep the throttle in the slow position when not in use Always keep a safe distance between two or more operators when working together simultaneou
28. om air discharge areas Rotating fan will cause serious injury Before performing any service or maintenance disconnect gt spark plug wire Make sure throttle is in STOP position Read and understand the Owners Manual Store your Owners Manual in a safe place 720602 ROTATING BLADES MAY CAUSE SERIOUS PERSONAL INJURY KEEP ALL BODY PARTS AWAY KEEP LARGE OR HARD OBJECTS FROM ENTERING MACHINE INTENDED USE IS FOR GRASS AND LEAVES DO NOT OPERATE WITHOUT DISCHARGE CHUTE General Safety Rules warninc pancer 1 Read Sad understand menial DO NOT USE THE SHREDDING TRUCKLOADER IF THE MUFFLER IS DEFECTIVE OR MISSING 2 Wear eye hearing and breathing protection proper z clothing and footwear A A Warnings Don ts 3 While operating the machine maintain a safe operating Don t attempt to remove materials from si 4 WARNING position secure footing and good balance at all times intake or discharge when Shredding i TruckLoader is running or fan is 4 Keep area clear of children pets and bystanders rotating Explosive Gas can cause fires and severe acid bums Charge battery only in a well ventilated area Keep sources of ignition away 5 Never attempt to use an incomplete machine or one fitted i ed Don t install or remove components with an unauthorized modification while Shredding TruckLoader is running A Explosive Gas 6 Avoid
29. oned between the 1st and 2nd coil of the Discharge Extension Hose Once in position tighten the clamp to ensure a firm connection of the two parts 6 Insert the opposite end of the Discharge Extension Hose into the receiver box on your truck In the event the Hose is too long for your application you can choose to cut it to a shorter length If you shorten the length of this hose make sure enough hose is left to properly install and secure it into the truck 7 Once the Hose is properly fit into your truck secure it in place with a rope bungee cord etc as required to secure it in place 8 Make sure the Discharge Nozzle and Discharge Extension Hose is positioned to ensure a straight flow from the TruckLoader into your receiver box 9 Once everything has been properly positioned and secured reconnect both spark plug wires on your engine Maintenance and Operation 1 Be sure to check the positioning and all connections of your TruckLoader before starting 2 To increase the life of your Discharge Extension Hose periodically rotate the position of this hose This can be accomplished by repeating the Assembly instructions specified above Operation A Starting the Engine 1 Check the oil level Add oil if necessary 2 Check the air cleaner for dirty loose or damaged parts Clean or replace parts as necessary 3 Check the air intake and cooling area for dirt or debris and clean as necessary 4 Move the
30. ough which the unit can be secured to an appropriate mounting surface For your convenience 4 Bolts 64123 234 and 4 Nuts 64268 07 have been provided for the installation For the purpose of lifting your unit two options have been provided for you The first option is a lifting lug found near the engine muffler mounted on the backside of the Housing Assembly This lug has been designed to hold a maximum of 500 pounds The second option is the lifting bars which are incorporated in the frame and found on either side of the Housing Assembly FRAME DECK MOUNTING HOLES HOSE CLAMP Insert the Intake Nozzle into the end of the hose opposite the hose flange as shown Using the second Hose Clamp secure the hose to the Intake Nozzle by wrapping the clamp around the hose portion covering the Intake Nozzle and tighten Install the Intake Nozzle Handle as shown To secure the Intake Nozzle Handle to the Intake Nozzle insert the 4 Bolts 64262 020 and 4 Nuts 64229 03 that have been provided for the installation HOSE FLANGE ASSEMBLY HOSE CLAMP FRAME LIFTING BARS Figure 2 C Mounting the Boom Arm Assembly to the Housing Boom Column Figure 3 1 Slide a Thrust Washer 720428 onto the shaft of the Boom Column Assembly Apply some 2 lithium based grease to the shaft of the Boom Column Install the Boom Arm Assembly 720285 17 onto the shaft of the Boom Column Assembly Slide a second Thrust Was
31. rk plug wires to the spark plugs on the engine USE HOLE IN FAN BACK PLATE TO ALIGN FAN HUB KEYWAY WITH KEY ON THE CRANK SHAFT Figure 7 INLET ASSEMBLY 12 B Liner Replacement Figure 7 1 Complete Steps 1 thru 7 found in section A Removing and Replacing the Fan and Talon Ring Unbolt and remove the hardware securing the Liner to the Housing Remove the Liner from the housing by wrapping it and pulling it through the front of the housing When installing the new Liner into the Housing make sure the chamfered edge of the liner is installed in the vertical position at the discharge opening of the housing As you position the Liner against the wall of the Housing make sure the holes of the liner line up with the slots in the Housing Secure the Liner to the Housing one hole at a time with the 10 bolts washers and nuts When installing the hardware insert the bolts through the inside surface of the liner and install the washers and nuts to the outside face of the Housing Complete Steps 8 thru 13 found in section A Removing and Replacing the Fan and Talon Ring C Oil and Filter Change 13 1 Oil Change Change oil after every 100 hours of operation more frequently under severe conditions Refill with service class SG SH SJ or higher oil as specified in the Viscosity Grades above Change the oil while the engine is still warm The oil will flow more freely and carry away more i
32. ry The standard spark plug is a Champion RC12YC Kohler Part No 12 132 02 S A high performance spark plug Champion Premium Gold 2071 used on Pro Series engines Kohler Part No 12 132 06 S is also available Equivalent alternate brand plugs can also be used Main Element Removing Elements Figure After the main element is removed check the a condition of the inner element It should be replaced whenever it appears dirty typically every other time the main element is replaced Clean the area around the base of the inner b element before removing it so dirt does not get into the engine c Inner Dust Ejector d Valve Heavy Duty Air Cleaner Assembly Figure Do not wash the paper element and inner element or use pressurized air this will damage the elements Replace dirty bent or damaged elements with new genuine Kohler elements as required Handle new elements carefully do not use if the sealing surfaces are bent or damaged Check all parts for wear cracks or damage Replace any damaged components Install the new inner element Kohler Part No 25 083 04 S followed by the outer element Kohler Part No 25 083 01 S Slide each fully into place in the air cleaner housing Reinstall the end cap so the dust ejector valve is down and secure with the two retaining clips See Heavy Duty Air Cleaner Assembly Figure Before removing the spark plug clean the area around the base of the plug to keep dirt
33. sly WARNING A DANGER IF THE SHREDDING TRUCKLOADER IS USED IMPROPERLY OR SAFETY PRECAUTIONS ARE NOT FOLLOWED THE USER RISKS SERIOUS INJURY TO THEMSELVES AND OTHERS READ AND UNDERSTAND THE FOLLOWING BEFORE ATTEMPTING TO OPERATE THIS SHREDDING TRUCKLOADER c A Engine Fuel Warnings Don ts Don t fuel engine or check fuel while smoking or near an open flame or other ignition source Stop engine and be sure it is cool before refueling Don t leave the engine running while the Shredding TruckLoader is unattended Don t transport the Shredding Truckloader while the engine is running Don t start run this TruckLoader indoors or in an improperly ventilated area as poisonous carbon monoxide and other gasses are emitted Don t run engine when electrical system causes spark outside the cylinder During periodic checks of the spark plug keep plug a safe distance from cylinder to avoid ignition of evaporated fuel from cylinder Don t check for spark with spark plug or plug wire removed and grounded Use an approved tester Sparks can ignite fumes Don t run engine when the odor of gasoline is present or other explosive conditions exist Don t operate the unit if gasoline is spilled Clean up spill completely before starting engine Don t refuel indoors or in an improperly ventilated area Don t operate your Shredding TruckLoader if there is an accumulation of debris around the
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