LH775 Service Manual - kohlerengines.com

1 LH775 Service ManualIMPORTANT: 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 cations11 Tools and Aids14 Troubleshooting18 Air Cleaner/Intake19 Electronic Fuel Injection (EFI) System45 Lubrication System47 Electrical System51 Starter System55 Cooling System59 Disassembly/Inspection and Service75 Reassembly66 690 07 Rev. PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property : is used to notify people of important installation, operation, or maintenance information. WARNINGE xplosive Fuel can cause fi res and severe not fi ll fuel tank while engine is hot or is extremely fl ammable and its vapors can explode if ignited.

2 Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. WARNINGR otating Parts can cause severe away while engine is in hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed. WARNINGC arbon Monoxide can cause severe nausea, fainting or inhaling exhaust exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. WARNINGA ccidental Starts can cause severe injury or and ground spark plug lead(s) before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s).

3 2) Disconnect negative ( ) battery cable from battery. WARNINGHot Parts can cause severe not touch engine while operating or just after operate engine with heat shields or guards removed. WARNINGC leaning Solvents can cause severe injury or only in well ventilated areas away from ignition cleaners and solvents are extremely fl ammable. Follow cleaner manufacturer s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. CAUTIONE lectrical Shock can cause not touch wires while engine is running. CAUTIOND amaging Crankshaft and Flywheel Can Cause Personal Injury!Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing fl ywheel. WARNINGHot liquid can cause severe not loosen radiator cap while engine is operating or warm to coolant can get extremely hot from operation.

4 Turning radiator cap when engine is hot can allow steam and scalding liquid to blow out and burn you severely. Shut off machine. Only remove radiator cap when cool enough to touch with bare hands. Slowly loosen cap to fi rst stop to relieve pressure before removing completely. WARNINGE xplosive Fuel can cause fi res and severe system ALWAYS remains under HIGH a shop towel completely around fuel pump module connector. Press release button(s) and slowly pull connector away from fuel pump module allowing shop towel to absorb any residual fuel in high pressure fuel line. Any spilled fuel must be completely wiped up 690 07 Rev. --3 MaintenanceMAINTENANCE INSTRUCTIONS WARNINGB efore working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative ( ) battery cable from battery.

5 Accidental Starts can cause severe injury or and ground spark plug lead(s) before 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 SCHEDULEE very 200 Hours1 Change oil and oil fi SystemEvery 200 Hours Replace fuel fi 250 Hours1 Replace air cleaner element and check inner Cleaner/IntakeEvery 500 Hours1 Replace air cleaner inner Cleaner/IntakeEvery 500 Hours Replace spark plugs and set SystemEvery 1000 Hours Change engine SystemEvery 1500 Hours1 Replace unique Electronic Fuel Injection (EFI) fuel fi Perform these procedures more frequently under severe, dusty, dirty PARTSK ohler genuine Service parts can be purchased from Kohler authorized dealers.

6 Find your local Kohler Engines dealer at or call 1-800-544-2444 ( and Canada).66 690 07 Rev. RECOMMENDATIONSWe recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) Service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below. FUEL RECOMMENDATIONS WARNINGE xplosive Fuel can cause fi res and severe not fi ll fuel tank while engine is hot or is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning : E15, E20 and E85 are NOT approved and should NOT be used; effects of old, stale or contaminated fuel are not must meet these requirements: Clean, fresh, unleaded gasoline.

7 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 overfi ll fuel tank. Do not use gasoline older than 30 engine will be out of Service for 2 months or more follow procedure 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).2. 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 Disconnect negative (-) battery Store engine in a clean, dry 690 07 Rev.

8 --5 Specifi cations66 690 07 Rev. DimensionsOptional Oil ( )Oil ( ) ( ) ( )CLMounting Hole "A" ( )Center of Air ( )Air Intake Optional OrientationEngine Mounting ( )Oil Drain ( )Mounting ( ) ( )Mounting Hole "A"Mounting (.157) ( ) ( ) ( ) ( ) ( )Option1/4 Inch Square Key5/8-18 UNF Thread7/16-20 Thread ( )Coolant Overfl ow ( )Oil ( ) ( )OverallFuel ( )2X ( ) ( )23( )Rain Cap ( )Overall without Rain ( )OverallMounting HoleLCCLM ounting HoleDimensions in equivalents shown in (). ( )Mounting Hole "A"4X 3/8-16 UNC-2B ( )Oil ( )2X ( )Exhaust Pilot( )Bolt ( ) Oil Filter Removal( ) Bolt Circle( )4X 45 2X 45 2X 60 4x 7/16-14 UNC-2B InchOil Filter SidePTO SideTop ViewStarter SideFlywheel End6 Specifi 690 07 Rev. --GENERAL SPECIFICATIONS3,6LH775 Bore83 mm ( in.)Stroke69 mm ( in.)Displacement747 cc ( cu. in.)

9 Oil Capacity (refi ll) L ( qt.)Maximum Angle of Operation (@ full oil level)420 TORQUE SPECIFICATIONS3,5LH775 Intake ManifoldIntake Manifold Fastener (torque in 2 increments)fi rst to N m (66 in. lb.)fi nally to N m (88 in. lb.)Thermostat Housing Mounting N m (55-65 in. lb.)Air Cleaner Elbow Mounting N m (88 in. lb.)Closure PlateClosure Plate N m (216 in. lb.)Connecting RodCap Fastener (torque in increments) N m (100 in. lb.)CrankcaseBreather Cover N m (95 in. lb.) into new N m (65 in. lb.) into used holeOil Drain N m (10 ft . lb.)Cylinder HeadCylinder Head Fastener (torque in 2 increments)fi rst to N m (150 in. lb.)fi nally to N m (300 in. lb.)Rocker Pivot N m (100 in. lb.)3 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insuffi cient Lubricate threads with engine oil prior to Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards.

10 Details on Certifi ed Power Ratings can be found at IDENTIFICATION NUMBERSK ohler engine identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair, ordering correct parts, and engine .. LH775 Liquid CooledHorizontal ShaftNumerical DesignationSpecifi cation .. LH775 -0001 Serial .. 3923500328 Year Manufactured Code Factory Code Code Year 39 2009 40 2010 41 20117 Specifi cations66 690 07 Rev. SPECIFICATIONS3,5LH775 Electric StarterStarter Thru N m (49-79 in. lb.)Starter Mounting N m (135 in. lb.)Starter Brush Holder N m (22-29 in. lb.)Starter Solenoid N m (35-53 in. lb.)Starter Solenoid Positive (+) Brush Lead Retaining N m (71-97 in. lb.)Fan/FlywheelRear Fan Shaft to Mounting Bracket N m (140 in.)