Kohler K91RT User manual

-KOHLER

ENGINES

4-CYCLE

•

SHORT-STROKE

•

AIR-COOLED

M0DEL

1.8

H.P.

1800

R.P.M.

K91RT

2.6

H.P.

2400

R.P.M.

3.S

H.P.

3200

R.P.M.

SPEC.

NO.

31600-A

3.8

H.P.

3600

R.P.M.

MANUFACTURED FOR

4.0

H.P.

4000

R.P.M.

THE

ESKA

COMPANY

Kohler

engines

are

manufactured

under

the

super-

vision

skilled

technicians.

The

engines

are

precision

units,

machined

and

assembled

deliver

many

hours

reliable

service.

All

components

are

produced

under

rigid

inspection,

tested

under

load

conditions,

and

adjusted

meet

exact

specifications

before

shipment

made.

Kohler

engines

are

solidly

constructed

with

heavy

duty

cast

iron

block,

employing

modern

short

stroke

design,

and

built-in

mechanical

governor.

This

folder

will

assist

you

offering

the

correct

procedures

for

care

Kohler

engines.

For

K91

engine

service

manual

with

complete

operation,

main-

tenance,

overhaul,

and

parts

identification

information,

send

$1.50

to:

Engine

Service

Department

Kohler

Co.,

Kohler,

Wisconsin

OPERATING INSTRUCTIONS

Before

Starting

Remove

oil filler

cap

and

check

oil level.

Add

clean

oil

mark

indicated

dipstick

(SAE

5W-20).

Oil

should

not

over

full

mark.

Keep

fuel

tank

filled

with

clean,

fresh

gasoline

regular

grade

prevent

condensation

cold

weather.

NOT

MIX

OIL

WITH

GAS-

OLINE.

sure

fuel

tank

cap

vent

hole

open.

Vent

hole

can

freeze

over

while

plowing.

Remove

both

plugs

reduction

gear

unit

and

add

oil,

(same

grade

used

crankcase)

oil level hole.

sure

that

vent

hole

oil fill

plug

open.

oil

bubbles

out

vent

hole

oil fill

plug,

there

too

much

oil.

Break

rotor

blade

free

before

starting.

Start

Open

valve

sediment

bowl.

choke

lever.

Choking

may

necessary

due

variations

temperature,

grade

fuel,

etc.

Little

choking

will

necessary

when

engine

warm.

Experience

will

teach

you

the

degree

necessary

under

varying

conditions.

Open

remote

throttle

about

half

way

until

engine

starts,

then

set

desired

speed.

Extreme

Cold

Idle

screw

set

factory

for

fast

idle.

throttle

and

set

full

choke.

When

engine

has

started,

open

choke

slowly,

making

adjustments

engine

warms

up.

Use

Autolite

AR8

spark

plug

equivalent.

Below

_250

Apply

heat

engine

cylinder

head,

spark

plug,

and

oil

pan.

Engine

will

start

-40 0

with

heat

application.

Give

starter

pulley

quick,

steady

pull.

not

jerk

pull

retractable

starter

end

cable

-return

handle

slowly.

NOT

ALLOW

HANDLE

SNAP

BACK.

Slowly

return

choke

open

position

engine

warms

up.

Stop

Whenever

possible,

allow

engine

idle,

with

load,

before

stopping.

Press

red

breaker

point

"STOP"

button

and

hold

until

engine

completely

stopped.

See

Instructions

for

Storing

engine

taken

out

service

for a

considerable

length

time.

Precautions

Stop

engine

before

filling fuel

tank.

Avoid

spilling

gasoline

hot

engine.

Always

use

fresh,

clean

gasoline.

Avoid

lnJuries.

Always

disconnect

spark

plug

cable

before

making

any

adjustment

machine

powered

engine.

Cont.

page

BrentChalmers.com

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BrentChalmers.com

ESKA

MODEL K91RT -

SPEC.

NO.

31600-A

PARTS

LIST

Item I

Quan-I

Part

I·

Item

Quan-

Part

Item

Quan-

Part

No.

tity

No.

Description

No.

tity

No.

Description

No.

tity

No.

Description

----------

1220541

Head,

cylinder

220132

Bushing,

governor

AIR INTAKE

GROUP

100 1

220156

Bracket,

speed

con'trol

1 2

X-18-2

Washer,

lock

DIPSTICK

GROUP

101 1

220380

Linkage,

governor

2 2

X-51-43

Screw,

R.H.M.

8-32xYs

I1I

A-220092

Dipstick-assembly

220873

Disc,regulating

50 1

220854

Cover,

duct

51 1

220855

Body,

duct

EXHAUST

GROUP

IGNITION

GROUP

235308

Element

X-81-1

Nut,

hex.

7.4:-20

220537

Gasket

54 1

220122

Gasket,

muffler

X-5-1

Screw,

H.C.

7.4:-20x%

55 2

220133

Stud,

muffler

104 1

X-20-1

Washer,

lock

7.4:

BAFFLES &

SHROUD

GROUP

X-22-18

Washer,

lock

I.E.T.

5 2

X-132-1

Screw,

H.C.

>i-20xYs

A-220145

Muffler-assembly

X-25-48

Washer

X-132-5

Screw,

H.C.

>i-20x%

FLYWHEEL

GROUP

X-25-63

Washer

220049

Baffle,

head

Washer,

lock

Vt6

105 2

X-67-22

Screw,

self

tapping

220054

Baffle,

cylinder

60 1

X-23-1

102 1

X-67-37

Screw,

self

tapping

10 1

220220

Housing,

blower

61 1

X-43-3

Key,

woodruff

8-32x%

62 1

X-88-2

Nut,

hex.

Vt6-2O

103 4

X-131-1

Screw,

F.H.M.

10-24xYs

BREATHER &VENT

GROUP

63 1

A-220636

Flywheel-assembly

(w/washer)

11 1

X-20-1

Washer,

lock

7,{

106

X-489-1

Rod,

breaker

12 1

X-81-1

Nut,

hex.

7,{-20

FUEL

TANK

FITTINGS

GROUP

107 1

A-220136

Cover,

breaker-assy.

13 1

210256

Filter

64 2

X-5-7

Screw,

H.C.

>i-20x1

108 1

220174

Gasket

14 1

220357

Plate,

breather

65 2

X-101-8

Nut,

stop

>i-20

109 1

A-220409

Stator-assembly

15 1

220358

Cover,

valve

66 1

X-217-6

Nipple

115 1

220435

Coil

16 1

220368

Stud,

cover

67 1

210101-A

Filter,

fuel-assenbly

116 1

220434

Condenser

17 1

220369

Seal,

breather

220097

Line,

fuel 110 1

A-220443

Cable,

hi-tension

18 2

220370

Gasket,

cover

220154

Strap,

tank

111 1

A-220474

Breaker-assembly

19 1

220379

Reed,

breather

72 1

220158

Bracket,

tank

L.H.

112 1

A-220512

Lead,

breaker

74 2

220166

Webbing

220856

Spring,

stop

control

CAMSHAFT &VALVES

GROUP

73 1

220514

Bracket,

tank

R.H.

220857

Bracket,

stop

control

20 1

220008

Valve,

intake

220547

Sleeve

113 1

240667

Plug,

spark

220009

Valve,

exhaust

220786

Nut

114

275183

Clip,

cable

22 2

220010

Spring,

valve

70 1

A-220852

Tank,

fuel-assembly

23 2220011

Retainer,

spring

220853

Cap,

tank

NAMEPLATE

GROUP

24 2

220013

Tappet,

valve

231510

Elhow,

compression

25 2

220052

Pin,

valve

lock

117

X-S13-1

Screw,

sheet

metal

220053

Pin,

camshaft

GEAR REDUCTION

GROUP

-7x3/g

27 1

A-220140

Camshaft--assembly

76 2

X-5-4

Screw,

H.C.

>i-20x1>i

118 1

220630

Nameplate

77 4

X-6-23

Screw,

H.C.

5j6-24x%

220673

Decal,

H.P.

CARBURETOR

GROUP

78 4

X-20-1

Washer,

lock

X-140-1

Screw.

sltd.

hd.

79 2

X-21-1

Washer,

lock

OIL

PAN

GROUP

7,{-20x%

X-75-2

Plug,

pipe

)4' 120

X-75-2

Plug,

pipe

)4'

29 1

210223

Gasket,

carburetor

X-81-1

Nut,

hex.

)4'-20

122 4

X-154-1

Screw,

H.C.

%;-18xYs

E-220517

Carburetor-assembly

81 1

X-230-11

Plug,

expansion

113 1

220167

Pan,

oil

231324

Decal,

choke

82 1

X-271-11

Seal,

gear

cover

121 1

220775

Gasket,

pan

231510

Elbow,

compression

X-271-15

Seal,

gear

housing

28 1

220547

Sleeve

D-997

Washer,

copper

220786

Nut

85 1

205013

Plug,

pipe

PISTON

ROD

GROUP

1220211

Housing,

gear

124 1

220467

Ring

set-std.

CRANKCASE

GROUP

220212

Cover,

gear

B-220070

Rod,

connecting-assy.

X-5-1

Screw,

H.C.

7.4:-20x%

220213

Gear,

drive

125 1

B220111

Connecting

rod

X-25-55

Washer,

copper

7.4:

220216

Bushing,

drive

shaft

126

1220492

Lock,

connecting

rod

X-271-15

Seal,

front

oil 91 1

220218

Gasket,

cover

127 2220491

Screw,

connecting

rod

X-271-16

Seal,

rear

oil 2

220790

Stud

128 1

A-220103

Piston-assy.,

std.

X-301-6

Button,

plug

220858

Shaft,

gear

129 2

220004

Retainer,

200110

Bearing,

ball

Pour

engine

oil

into

gear

housing

filler

hole

130 1

220003

Pin,

piston

1220071

Gasket,

bearing

plate

until

oil

runs

from

oil

level

hole

lower

end.

220385

Plate,

bearing

RETRACTABLE STARTER

GROUP

41 1

A-220459

Block,

cylinder-assy.

GOVERNOR

GROUP

131 4

X-19-1

Washer,

lock

CRANKSHAFT

GROUP

92 1

X-5-7

Screw,

H.C.

>i-20x1

X-25-7

Washer

X-25-63

Washer

7,{

132 4

X-50-2

Screw,

R.H.M.

10-32x%

I1I

220433

Crankshaft

X-67-5

Screw,

drive

133 1

C-220589

Starter,

recoil-assy.

X-81-1

Nut,

hex.

>i-20

134 1

A-220594

Cup,

drive

/screen

CYLINDER HEAD

GROUP

X-269-13

Ring,

snap

1220124

Gasket,

head

95 1

220119

Spring,

governor

220257

Screw,

H.C.

%;x18x1->i

220126

Lever,

governor

220151

Gasket

set

220S34

Washer

1220131

Shaft.

governor

Indented

part

numbers

and

descriptions

are

components

preceding

assembly.

Order

parts

from

your

nearest

Kohler

dealer

giving

part

number

and

description

part

and

model

number,

specification

number

and

serial

number

engine.

BrentChalmers.com

GEAR REDUCTION

The

reduction

unit

is a

gear

type

running

oil.

Tl,1e

drive

gear

machined

the

crankshaft

and

the

driven

gear

keyed

and

pressed

onto

the

power-take-off

shaft.

The

shaft

supported

two

bronze

bearings

located

the

gear

housing

and

the

gear

cover.

Before

Operating

Remove

oil fill

plug

and

oil level

plug

and

fill

gear

unit

oil level hole.

Use

same

grade

oil

recommended

for

engine.

The

reduction

gear

vented

through

the

oil fill

plug.

This

vent

should

checked

daily

see

that

open.

Change

reduction

gear

oil

every

100

operating

hours.

Service

Remove

four

cap

screws

from

gear

housing,

slide

off

cover

and

remove

power-take-off

with

driven

gear.

Remove

four

cap

screws

that

hold

gear

hop.sing

engine

block.

Use

socket

wrench.

Wash

all

parts

and

inspect

shaft,

bushing,

and

gears

for

wear.

Replace

all

worn

parts,'

Remove

old

oil

seals

and

install'new

seals

(flat

side

out)

gear

housing

and

reduction

.gear

cover.

Assembly

'Wrap

tape

around

crankshaft

gear

protect

oil

seal,

slide

gear

reduction

housing

over

shaft

and

attach

block.

Two

lock

washers

are

used

outside

and

copper

washers

inside.

Place

thrust

washers

shaft,

one

each

side

reduction

gear.

Tape

should

wrapped

around

shaft

prevent

keyway

from

damaging

oil

seal

while

cover

installed

power-take-off

shaft.

Install

gaskets

cover

and

place

assembly

position

gear

housing.

CONTACT YOUR

NEAREST

KOHLER

DEALER

FOR REPAIR

PARTS

KOHLER

CO.

Established

1873 KOHLER,

WIS.

KoHLE R oFKoHLER

EN405

6M-7-62-Z

LITHO

BrentChalmers.com

Crankcase

and

air

cleaner

must

properly

serviced

all

times.

Dirt

drawn

through

im-

properly

serviced

air

cleaner

can

ruin

engine

afew

operating

hours.

c. Allow

engine

warm

before

applying

work

load.

Keep

cylinder

block,

flywheel,

cylinder

hea.

cooling

fins,

and

rotating

air

screen

free

ice

and

snow.

not

operate

speeds

greater

than

governor

setting

run

continuously

under

maximum

load.

MAINTENANCE

Each

Day

Check

fuel

supply

and

oil level

crankcase.

Add

oil

only

needed

keep

level

between

marks

oil

gauge.

Clean

oil,

dirt,

and

snow

from

external

surface

power

unit.

Check

air

intake

and

cooling

fins

for

obstructions

and

ice.

Every

Operating

Hours

Change

oil

crankcase.

Check

gasket

joints

between

air

cleaner,

car-

buretor,

and

air

intake

manifold.

Every

100

Operating

Hours

Perform

hour

service

and

addition:

File

electrode

areas

and

regap

spark

plug

.025.

Use

Autolite

AR-8

plugs,

equivalent,

for

cold

weather

operation.

Remove,

clean,

and

replace

sediment

bowl.

Check

breaker

points

and

regap

.020.

Oil recoil

starter

through

hole

indicated

starter

housing.

Use

lube

equivalent

grade

oil.

Instructions

for

Storing

engine

out

service

for a

considerable

length

time,

the

following

procedure

recom-

mended:

Drain

fuel

tank.

Drain

carburetor

pressing

bowl

drain

button

bottom

carburetor

bowl.

Remove,

clean,

and

replace

sediment

bowl.

Clean

exterior

surfaces

engine.

Spread

light

film

oil

over

any

exposed

sur-

faces

engine

subject

corrosion.

Pour

tablespoon

oil

into

spark

plug

hole

and

crank

engine

slowly

hand.

Replace

plug.

not

expose

elements-store

dry

place.

TROUBLE

SHOOTING

Following

is a

list

troubles

which

may

occur

through

average

use

and

normal

wear:

Hard

Starting

Faulty

Ignition

(1)

Loose

grounded

high

tension

breaker

point

leads.

(2)

Improper

breaker

point

gap.

(3)

Defective

breaker

points.

(4)

Faulty

spark

plugs.

(5)

Faulty

condenser

coil.

(6)

Incorrect

spark

timing.

(7)

Check

ignition

system

for

moisture.

Faulty

Carburet

ion

(1)

Gasoline

not

getting

carburetor.

(a)

Ice,

dirt

gum

deposits

In fuel line.

(2)

Dirt

carburetor.

(3)

Carburetor

improperly

adjusted.

Compression

Loss

(1)

Valves

leaking

sticking.

(2)

Rings

worn.

(3)

Head

gasket

leaking.

Overheating

Insufficient

cooling

air

available.

Dirty

clogged

intake

screen,

shroud

.cooling

fins.

Improper

fuel.

Fuel

mixture

too

lean.

Improper

ignition

timing.

Backfiring

Fuel

mixture

too

lean.

Sticky

intake

valve.

Improper

ignition

timing.

Point

gap

open

too

far.

Occasional

Missing

High

Speed

Spark

plug

gap

too

wide.

Improper

carburetor

adjustment

lack

fuel.

Wrong

type

spark

plug.

Improper

ignition

timing.

Missing

Under

Slow,

Hard

Pull

Spark

plug

gap

too

wide.

Pitted

breaker

points.

BrentChalmers.com

Partially

fouled

spark

plug.

Defective

ignition

timing.

Knocking

Fuel

octane

rating

too

low.

Use

good

grade

regular

gasoline.

Improper

ignition

timing.

Overheated

engine.

Loose

connecting

rod.

Excessive

carbon

combustion

chamber.

Lack

lubrication.

Operating

Erratically

Clogged

fuel line.

Water

fuel.

Faulty

choke

control.

Improper

fuel

mixture.

Loose

ignition

system

connection.

Air

leaks

manifold

carburetor

connections.

Engine

Will

Not

Idle

Improper

carburetor

idling

adjustment.

Carburetor

jets

clogged.

Spark

plug

gap

too

small.

.025.

Leaking

carburetor

manifold

gaskets.

Sticking

leaking

valves.

Weak

coil

condenser.

Engine

Stops

While

Operation

Check

fuel

tank

cap

vent

hole.

Air

cleaner

can

clogged

with

fine

snow.

CARBURETOR ADJUSTMENTS

The

carburetor

adjusted

the

factory

and

under

normal

operating

conditions

will

not

require

readjust-

ment.

adjustment

necessary

because

fuel

values

and/

air

conditions,

the

following

procedure

recom-

mended:

Turn

high

speed

adjustment

screw

(center

ver-

tical

screw

top

carburetor)

counter-clockwise

two

full

turns

from

closed

position

and

start

engine.

After

engine

has

reached

normal

operating

tem-

perature,

accelerate

and

check

response.

Operate

engine

under

full

load

and

adjust

high

speed

needle

for a

slightly

richer

mixture

for

improved

cooling

and

greater

power.

engine

misses

and

backfires,

high

speed

mixture

too

lean.

correct-high

speed

adjustment

screw

should

turned

counter-clockwise,

74:

turn

time,

until

condition

corrected.

engine

shows

sooty

exhaust

and

sluggish,

mixture

too

rich.

correct-high

speed

adjustment

screw

should

turned

clockwise

until

engine

runs

smoothly.

make

final

check

high

speed

adjustment,

operate

under

full

load

and

make

corrections

achieve

smooth

operation.

Idle

speed

controlled

stop

screw

car-

buretor

throttle

shaft

and

should

set

speed

not

less

than

1000

RPM.

Adjustments

idle

mixture

screw

(angled

screw

side

carburetor)

and

idle

stop

screw

should

made

the

same

time

each

affects

the

other.

Adjust

until

engine

idles

smoothly.

WARNING:

Do not use force on high speed needle

idle

screw-they

will

damaged.

RECOIL

STARTER

The

starter

has

die

cast

aluminum

housing.

friction

shoe

assembly,

under

spring

tension,

used

engage

the

drive

cup

when

starter

handle

pulled.

The

drive

cup

held

place

engine

the

flywheel

nut.

the

cup

engaged

the

crankshaft

keyway

prevent

slippage

the

drive

cup.

Align

Starter

Place

desired

position

blower

housing

with

centering

engaged

center

hole

crankshaft.

centering

too

short

reach

crankshaft,

pull

out

correct

length

with

pair

pliers.

Operating

Tips

sure

starter

screen

kept

clean

when

engine

operating.

Severe

damage

may

result

from

overheating.

After

starting

engine,

return

cable

slowly.

Re-

leasing

handle

when

cable

extended

will

shorten

life

starter.

Use

steady

pull

start

engine.

Jerking

cable

the

end

will

result

wear.

Pull

handle

that

cable

will

remain

centered

guides.

for

any

reason

recoil

starter

should

not

operate,

starter

assembly

can

removed

and

engine

cranked

with

rope.

The

starter

cup

will

serve

rope

pulley.

BrentChalmers.com

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