XT8 - KOHLER - Free user manual and instructions

USER MANUAL XT8 KOHLER

Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

Warranty coverage as outlined in the warranty card and on KohlerEngines.com. Please review carefully as it provides you specific rights and obligations.

Record engine information to reference when ordering parts or obtaining warranty coverage.

14 590 09 Rev. A Engine Model

à WARNING: A hazard that could result in death, serious injury, or substantial property damage.

A CAUTION: Ahazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

À warninc À warninc ul A warninc Explosive Fuel Carbon [7 Accidental

can cause fires Monoxide can Starts can cause and severe cause severe severe injury or

burns. nausea, fainting leath.

4 | Do not fil fuel or death Disconnect and tank while Avoid inhaling ground spark engine is hot or exhaust fumes. plug lead(s) running. before servicing.

Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buldings, auay from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent.

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled.

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (—)

battery cable from battery.

À warninG À caurion À warninc Rotating Parts Electrical Shock Hot Parts can can cause can cause injury cause severe

Se | severe injury. Do not touch burns. Stay away while 7 wires while sidté, | Do not touch engine is in engine is engine while opération. running. operating or just

Keep hands, feet, hair,

and clothing away from all moving paris to prevent injury. Never operate engine with covers, shrouds, or guards removed.

Never operate engine with heat shields or guards

California Proposition 65 Warning

Engine exhaust from this product contains chemicals known to State of California to cause cancer, birth defects, or other reproductive harm.

14 590 09 Rev. A Starter Handle EC Fuel Cap Ent Fuel Tank

Le] Air Cleaner E Fuel Shut-Of [| Primer Bulb El Spark Plug

tart Checklist 1. Check oil level. Add oil if low. Do not overfill. 2. Check fuel level. Add fuel if low. Check fuel system components and lines for leaks.

3. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly after storage)

4. Check that air cleaner components and all shrouds, equipment covers, and guards are in place and securely fastened

Check spark arrestor (if equipped).

14 590 09 Rev. A KohlerEngines.com 3

À warninc 5 Carbon Monoxide can cause AN. severe nausea, fainting or death.

Avoid inhaling exhaust fumes.

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is

odorless, colorless, and can cause death if inhaled.

À warninc Rotating Parts can cause severe <= iriur. ‘©; Stay away while engine is in operation.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed.

NOTE: Over priming may make it difficult to start engine. It is usually not necessary to prime a warm engine.

Choke position for starting may vary depending upon temperature and other factors. Once engine is running and warm, turn choke to OFF position.

Extend starter cord periodically to check its condition. If cord is frayed have it replaced immediately by a Kohler authorized dealer. 1. Turn fuel shut-off valve to ON position (if equipped). 2. Turn engine onfoff switch to ON position (if equipped). 3. Start engine as follows: a. Primer Bulb Models: Place finger or

thumb on center of primer bulb. Push primer 3 times.

or b. Manual Choke Models:

Cold engine: Place throttle control to FAST position. Pull choke control into CHOKE/ON position.

Warm engine: place throttle control to RUN/FAST position

c. Smart-Choke,, Models: this feature automatically adjusts choke on start-up.

4. Retractable Start: Slowly pull starter handle until just past compression-STOP! Return starter handle; firmly pull straight out to avoid excessive rope wear from starter rope guide.

Electric Start: Key switch (refer to operating instructions of equipment that this engine powers)

Gradually return choke control to OFF position after engine starts and warms up. Engine/equipment may be operated during warm up period, but it may be necessary to leave choke partially on until engine warms up.

Cold Weather Starting Hints

1. Use proper oil for temperature expected 2. Disengage all possible external loads.

3. Use fresh winter grade fuel. Winter grade fuel has higher volatilty to improve starting.

1. If possible, remove load by disengaging all PTO driven attachments.

Refer to operating instructions of equipment this engine powers. Do not operate this engine exceeding maximum angle of operation; see specification table. Engine damage could result from insufficient lubrication.

NOTE: Do not tamper with governor setting to increase maximum engine speed Overspeed is hazardous and will void warranty.

High Altitude Operation

This engine may require a high altitude carburetor kit to ensure correct engine operation at altitudes above 4000 ft.

{1219 meters). To obtain high altitude kit information or to find a Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 {U.S. and Canada)

This engine should be operated in its original configuration below 4000 ft. (1219 meters) as damage may occur if high altitude carburetor kit is installed and operated below 4000 ft. (1219 meters).

14 590 09 Rev. A Maintenance Instructions

e Before working on engine or equipment, disable Accidental Starts can cause engine as follows: 1) Disconnect spark plug A) | severe injury or death. lead(s). 2) Disconnect negative (-) battery cable & Disconnect and ground spark from battery.

Se | Plug lead(s) before servicing.

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual, however, warranty repairs must be performed by a Kohler authorized dealer found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada)

Maintenance Schedule

After first 3-5 Hours + Change oil

Every 25 Hours or Annually'

+ Service/replace precleaner.

+ Check air cleaner for dirty, loose or damaged parts.

Every 50 Hours or Annually

+ Replace fuel filter (if equipped).

Every 50 Hours or Annually'

+ Replace air cleaner element.

Every 100 Hours or Annually!

< Replace spark plug and set gap.

+ Clean spark arrestor (if equipped).

Every 100 Hours or Annually?

+ Check and adjust valve clearance when engine is cold.

+ Have combustion chamber decarbonized.

* Perform these procedures more frequently under severe, dusty, dirty conditions.

? Have a Kohler authorized dealer perform this service.

Oil Recommendations Check Oil Level

We recommend use of Kohler oils for best NOTE: To prevent extensive engine wear or performance. Other high-quality detergent damage, never run engine with oil level oils (including synthetic) of API (American below or above operating range Petroleum Institute) service class SJ or higher indicator on dipstick.

are acceptable. Select viscosity based on air temperature at time of operation as shown in table below.

Ensure engine is cool. Clean oil fill cap/dipstick areas of any debris.

1. Remove dipstick; wipe oil off.

a. 1/4 turn cap: reinsert dipstick into tube: press completely down and tu 1/4 turn.

b. Threaded cap: reinsert dipstick into tube: rest cap on tube, do not thread cap onto tube.

2. Remove dipstick; check oil level. Level should be at top of indicator on dipstick

3. If oil is low on indicator, add oil up to top of indicator mark.

4. Reinstall and secure dipstick.

14 590 09 Rev. A KohlerEngines.com 5

Change oil while engine is warm. Dipstick tube: . Clean area around oil fill cap/dipstick.

2. Remove oil fil cap/dipstick. Tilt engine on its side with air cleaner facing up. Drain oil into appropriate container.

3. After crankcase is drained completely, tit engine upright.

4. Fill crankcase with new oil. Level should be at top of indicator on dipstick.

5. Reinstall oi fill cap/dipstick and tighten securely.

6. Dispose of used oil in accordance with local ordinances.

Crankcase plug: 1. Disable engine by disconnecting spark plug

2. Clean area around oil fil cap/dipstick. Remove oil fill cap/dipstick

3. Remove crankcase plug on bottom of engine: drain oil into appropriate container.

4. Apply thread sealant around three full threads of drain plug: reinstall drain plug Torque to 120 in. lb. (13.6 N-m).

Fill crankcase with new oil. Level should be at top of indicator on dipstick.

. Reinstall oil fil cap/dipstick and tighten securely.

Dispose of used oil in accordance with local ordinances.

Explosive Fuel can cause fires and severe bus.

Do not fil fuel tank while engine is hot or running,

Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in

well ventilatéd, unoccupied buildings, away from sparks or lames. Spilled fuel could ignite if it comes in contact with hot parts or Sparks from ignition. Never use gasoline as a cleaning agent.

NOTE: E15, E20 and E85 are NOT approved and should NOT be used: effects of old, stale or contaminated fuel are not warrantable.

Fuel must meet these requirements: + Clean, fresh, unleaded gasoline. + Octane rating of 87 (R+M)/2 or higher.

Research Octane Number (RON) 90 octane minimum.

Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable.

Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved.

Do not add oil to gasoline. Do not overfil fuel tank. Do not use gasoline older than 30 days.

Explosive Fuel can cause fires and severe burns.

Le di di, | Do not fi tuel tank white engine is hot or running

Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in

well ventilated, unoccupied buildings, away from Sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent.

Ensure engine is cool. 1. Clean area around fuel cap.

2. Remove fuel cap. Fil to base of filer neck. Do not overfill fuel tank. Leave room for fuel to expand

3. Reinstall fuel cap and tighten securely.

Low permeation fuel line must be installed on carbureted Kohler Co. engines to maintain EPA and CARB regulatory compliance.

14 590 09 Rev. A Spark Plugs

Electrical Shock can cause injury. Do not touch wires while engine Clean out spark plug recess. Remove plug and replace.

is running. 1. Check gap using wire feeler gauge. Adjust gap, see specification table for adjustment.

2. Install plug into cylinder head. 3. Torque plug to 20 ft. Ib. (27 N-m).

NOTE: Operating engine with loose or damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.

Paper element cannot be bloun out with compressed air.

Loosen knob and remove air cleaner cover. Precleaner (if equipped): 1. Remove precleaner.

2. Replace or wash precleaner in warm water with detergent. Rinse and allow to air dry.

3. Reinstall precleaner into cover, aligning hole in precleaner with upper cover knob

1. Remove paper element from base and replace.

2. Install element with pleated side out and seat rubber seal onto edges of base.

1. Remove foam element from base and replace.

2. Install element with foam side out and seat rubber seal onto edges of base.

Reinstall air cleaner cover and secure with

14 590 09 Rev. A Breather Tube

Ensure both ends of breather tube are properly connected.

Air Cooling À warNING Hot Parts can cause severe burns. “= | Do not touch engine while operating or just after stopping.

Never operate engine with heat shields or guards removed.

Proper cooling is essential. To prevent over heating, clean screens, cooling fins, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. $ee Maintenance Schedule.

Repairs/Service Parts

We recommend that you use a Kohler authorized dealer for all maintenance, service, and replacement parts for engine. To find a Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 {U.S. and Canada).

If engine will be out of service for 2 months or more follow procedure below.

. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system failures due to untreated fuel are not warrantable).

. Change oil while engine is still warm from operation. Remove Spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil.

3. Disconnect negative (-) battery cable. 4. Store engine in a clean, dry place.

D KohlerEngines.com 7

Do not attempt to service or replace major engine components, or any items that require special timing or adjustment procedures. This work should be performed by a Kohler authorized dealer.

Dirtin Dirty Faulty No Improper Fuel Debris Incorrect Engine DirtyAir Spark Fuel Fuel Line Screen OilLevel Overloaded Cleaner _ Plug

i Oil Capacity |Spark Plu: je Stroke |Displacement ; p 9| of Operation (Refill) Gap |(@ full oil level} XT-6 2.56 in. 9.1 cu. in. xTR-6 | (65mm) | 4 ain, | (149 ce) 20 oz. 0.03 in. 20° XT7 275in. | (5 MM) 406 cu. in (COL) | (076 mm) XTR7 (70 mm) (173 cc)

*Exceeding maximum angle of operation may cause engine damage from insuficient lubrication. Additional specification information can be found in service manual at KohlerEngines.com.

Exhaust Emission Control System for models XT-6, XTR-6, XT-7, XTR-7 is EM for U.S. EPA, California, and Europe.

Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & 11995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com.

© 2011 by Kohler Co. All rights reserved. KohlerEngines.com 14 590 09 Rev. A