Kohler Aegis ELH775 Service Manual Download Page 103

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103

66 690 14 Rev. A

KohlerEngines.com

Summary of Contents for Aegis ELH775

Page 1: ...sure engine is stopped and level before performing any maintenance or service 2 Safety 3 Maintenance 5 Specifications 18 Tools and Aids 21 Troubleshooting 25 Air Cleaner Intake 26 Electronic Fuel Inje...

Page 2: ...s before servicing Before working on engine or equipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery WARNING Hot Parts can cause severe bu...

Page 3: ...ter Every 250 Hours1 Replace air cleaner element and check inner element Air Cleaner Intake Every 300 Hours2 Change oil and oil filter KOHLER PRO 10W 50 oil and KOHLER PRO filter Lubrication System Ev...

Page 4: ...approved and should NOT be used e ects 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 Resear...

Page 5: ...wheel Side F E G H I A B D C J K A 432 0 mm 17 01 in B 325 0 mm 12 80 in C 560 45 mm 22 07 in D 625 33 mm 24 62 in E 4 X 10 66 mm 0 42 in F 92 10 mm 3 63 in G 2 X 184 20 mm 7 25 in H 272 10 mm 10 71 i...

Page 6: ...ecifications KohlerEngines com 66 690 14 Rev A Engine Dimensions Oil Filter Side A B C D E F A 152 08 mm 5 99 in B 141 75 mm 5 58 in C 201 0 mm 7 91 in D 12 47 mm 0 49 in E 38 0 mm 1 50 in F 3 8 NPTF...

Page 7: ...ter C 177 80 mm 7 00 in Pilot D 4 X 3 8 16 UNC 2B in 17 0 mm 0 66 in Deep E 4 X 7 16 14 UNF 2B in 21 0 mm 0 82 in Deep F 30 G 45 H 2 X 45 I 3 8 NPTF Plug J Mounting Hole Center Line K 124 10 mm 4 89 i...

Page 8: ...2 79 in F 54 8 mm 2 16 in G 28 56 mm 1 13 in 0 13 mm 0 01 in H 24 94 mm 0 98 in 0 13 mm 0 01 in I 1 4 Inch Square Key J 7 16 20 UNF 2B in 38 1 mm 1 50 in Deep K 155 58 mm 6 13 in L 4 0 mm 0 16 in Pilo...

Page 9: ...9 Specifications 66 690 14 Rev A KohlerEngines com Engine Dimensions Top A B A Oil Fill Cap B Radiator...

Page 10: ...nd all horsepower hp references by Kohler are Certified Power Ratings and per SAE J1940 J1995 hp standards Details on Certified Power Ratings can be found at KohlerEngines com 5 Exceeding maximum angl...

Page 11: ...TORQUE SEQUENCES ELH775 Refer to Torque Specifications for torque values Closure Plate Fasteners 5 3 1 2 4 6 7 8 9 10 Cylinder Head Bolt Fasteners 1 1 2 4 3 4 2 3 Intake Manifold Mounting Fasteners 1...

Page 12: ...r Fastener torque sequence on page 10 10 7 N m 95 in lb into new hole 7 3 N m 65 in lb into used hole Breather Reed Retainer Fastener 4 0 N m 35 in lb Oil Sentry 4 5 N m 40 in lb Oil Drain Plug 13 6 N...

Page 13: ...2 N m 55 in lb into new hole 4 0 N m 35 in lb into used hole Rectifier Regulator Fastener 4 0 N m 35 in lb Oil Pump Mounting Screw 7 9 N m 70 in lb Oxygen Sensor Mu er is OEM Supplied Sensor Torque 18...

Page 14: ...shaft End Play free 0 070 0 590 mm 0 0028 0 0230 in Crankshaft Sleeve Bearing I D crankcase New Max Wear Limit 40 974 40 987 mm 1 6131 1 6136 in 41 000 mm 1 6141 in Crankshaft Bore in closure plate Ne...

Page 15: ...0 017 mm 0 0002 0 0007 in Piston Pin Bore I D New Max Wear Limit 17 006 17 012 mm 0 6695 0 6698 in 17 025 mm 0 6703 in Piston Pin O D New Max Wear Limit 16 995 17 000 mm 0 6691 0 6693 in 16 994 mm 0 6...

Page 16: ...ke Valve Guide I D New Max Wear Limit 7 038 7 058 mm 0 2771 0 2779 in 7 134 mm 0 2809 in Intake Valve Stem Diameter New 6 982 7 000 mm 0 2749 0 2756 in Exhaust Valve Guide I D New Max Wear Limit 7 038...

Page 17: ...English Fastener Torque Recommendations for Standard Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Ti...

Page 18: ...logy Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier Regulator T...

Page 19: ...nd brushes Individual component available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed positi...

Page 20: ...ng gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk c...

Page 21: ...that intermittently ground ignition kill circuit Seized internal engine components TROUBLESHOOTING GUIDE When troubles occur be sure to check simple causes which at first may seem too obvious to be co...

Page 22: ...ndications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged el...

Page 23: ...Make sure pinch clamp is closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side If...

Page 24: ...haft Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywh...

Page 25: ...l cause engine damage due to over heating 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...

Page 26: ...cause fires and severe burns Do not fill fuel tank while engine is hot or running EFI System Components I A B N E K O M G J L E L C E F H D E H F D I A Fuel Pressure Regulator B Electric Fuel Pump C...

Page 27: ...hes operating temperature an exhaust gas oxygen sensor provides feedback to ECU based upon amount of unused oxygen in exhaust indicating whether fuel mixture being delivered is rich or lean Based upon...

Page 28: ...ossible failure a rev limiting feature is programmed into ECU If maximum RPM limit 4500 is exceeded ECU suppresses injection signals cutting o fuel flow This process repeats itself in rapid succession...

Page 29: ...for speed at which engine is running At proper instant it interrupts flow of primary current in coil causing electromagnetic flux field to collapse Flux collapse induces an instantaneous high voltage...

Page 30: ...revent dirt from entering system Always depressurize fuel system through fuel connector before disconnecting or servicing any fuel system components Never attempt to service any fuel system component...

Page 31: ...rs 11 Manifold Absolute Pressure TMAP sensor input 12 Throttle Position Sensor TPS input 13 Crankshaft Position Sensor Ground 14 Coolant Temperature Sensor input 15 Ignition Switch Switched 12V 16 Pow...

Page 32: ...s besides permanent hour meter This system will NOT reset when battery is disconnected ECU Reset Procedure 1 Turn key ignition OFF 2 Install Red wire jumper from Kohler EFI service kit on to service p...

Page 33: ...ey Connector Y Fuel Injector 1 Z Fuel Injector 2 AA Ignition Coil 1 AB Ignition Coil 2 AC Crankshaft Position Sensor AD Oxygen Sensor AE Throttle Position Sensor AF TMAP Sensor AG Coolant Temperature...

Page 34: ...st accomplished by cleaning connection thoroughly prior to disassembly Contaminated sensor connections can cause premature engine faults Functionally testing sensor can no longer be done with simple r...

Page 35: ...allation process requires significant force so take care that all parts are aligned Tapping magnet assembly on can fracture damage brittle magnet within assembly and throttle body assembly and is NOT...

Page 36: ...CU and wiring harness are functioning 2 Check continuity in wire harness Ohms between Pin 3 at sensor connector and Black pin 11 connector at ECU should be near zero ohms If no continuity is measured...

Page 37: ...one closed loop Once in closed loop sensor voltage should cycle between about 100 to 250 mv and 700 to 900 mv If this cycling is not observed a determination must be made if problem is with engine or...

Page 38: ...inated gasoline Use high quality fuel Engine problem misfire Correct cause of misfire Excessive rich air fuel ratio Check for high fuel pressure Leaking injector Liquid fuel in vent line Wiring shorte...

Page 39: ...uity 6 Attach ohmmeter leads to 30 and 87 terminals in relay At first there should be no continuity Using a 12 volt power supply connect positive lead to 85 terminal and touch negative lead to 86 term...

Page 40: ...re from leakage can cause hot restart problems and longer cranking times Refer to Disassembly for removal of injector 1 Engine must be cool Depressurize fuel system through fuel connector 2 Disconnect...

Page 41: ...is faulty and needs to be replaced FUEL COMPONENTS Fuel Pump Fuel pumps are non serviceable and must be replaced if determined to be faulty If a fuel delivery problem is suspected make certain pump i...

Page 42: ...y intake manifold No specific servicing is required unless operating conditions indicate that it needs internal cleaning or replacement It can be detached by removing mounting screws and injector reta...

Page 43: ...ed sensor loose or faulty Faulty injectors Faulty spark plugs Engine Misses Hesitates or Stalls Under Load Fuel injector s fuel filter fuel line or fuel pick up dirty restricted Dirty air cleaner Insu...

Page 44: ...proper voltage 5 Check that fuses are good and that all electrical and fuel line connections are good 6 Test fuel pump and relay operation Diagnostic Fault Code Summary Fault Code Connection or Failur...

Page 45: ...good idea to write down codes as they appear as they may not be in numerical sequence b Code 61 will always be last code displayed indicating end of code transmission If code 61 appears immediately no...

Page 46: ...be damaged or routed near noisy signal coils alternator etc ECU to harness connection problem Code 0113 Component Intake Air Temperature TMAP Fault Intake Air Temperature Sensor Circuit High Voltage...

Page 47: ...Manifold Related Throttle shaft or bearings worn damaged Engine Wiring Harness Related ECU pins Black 10 12 and 16 damaged wiring connectors ECU pins Black 10 12 and 16 routed near noisy electrical s...

Page 48: ...stion air air cleaner dirty restricted intake leak throttle bores Base engine problem rings valves Exhaust system leak mu er flange oxygen sensor mounting boss etc Fuel in crankcase oil Code 0172 Comp...

Page 49: ...orted or open connection Conclusion Injector Related Injector coil shorted or opened Engine Wiring Harness Related Broken or shorted wire in harness ECU pin Black 5 Wiring from Ignition ECU Related Ci...

Page 50: ...ory and engine starts normally Clear code no other service required Code 0351 Component Ignition Coil Fault Cylinder 1 Ignition Coil Malfunction Condition Broken wire in harness may not be visible sho...

Page 51: ...lbs can be used for MIL as long as they do not draw more than 0 1 amps Bulb needs to be rated at 1 4 Watts or less or needs to have a total resistance of 140 or more LEDs typically draw less than 0 03...

Page 52: ...NOSTIC FAULT CODE SUMMARY CLEAR CODES NO REFER TO DIAGNOSTIC AID 3 RUN ON OPERATE AT VARIOUS SPEED LOAD CONDITIONS ARE FAULT CODES PRESENT NO END OF TEST REFER TO DIAGNOSTIC AID 4 CRANKSHAFT POSITION...

Page 53: ...is cool and level Clean oil fill dipstick areas of any debris 1 Remove dipstick wipe oil o 2 Reinsert dipstick into tube press completely down 3 Remove dipstick check oil level Level should be at top...

Page 54: ...h Teflon Loctite PST 592 Thread Sealant or equivalent to threads of switch 2 Install switch into tapped hole in breather cover 3 Torque switch to 4 5 N m 40 in lb Testing Compressed air a pressure reg...

Page 55: ...and Reassembly if stator replacement is necessary Rectifier Regulator Rectifier regulator is mounted on air cleaner bracket To replace disconnect plug s remove mounting screws and ground wire Battery...

Page 56: ...age increase will di er depending on state of charge in battery 2 If no voltage increase is seen at battery turn engine o and move voltmeter red lead to purple B lead on rectifier regulator and black...

Page 57: ...se Repeat applicable test procedure two or three times to determine condition of part NOTE A flashing LOW light can also occur as a result of an inadequate ground lead connection Make certain connecti...

Page 58: ...p to 0 76 mm 0 030 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip are an indication of gen...

Page 59: ...here wiring harnesses from engine and equipment are joined Separate connectors and remove white kill lead from engine connector Rejoin connectors and position or insulate kill lead terminal so it cann...

Page 60: ...EFI System Wiring Diagram If no continuity is found repair or replace electrical wiring harness If continuity is found refer to EFI System Ignition Coil Testing or exchange ignition coils side to sid...

Page 61: ...frayed or broken insulation Starter Switch or Solenoid By pass switch or solenoid with a jumper wire If starter cranks normally replace faulty components Consult with OEM electrical system service pro...

Page 62: ...king stop test and perform a battery load test Test 1 Conclusions If battery voltage is above 12 4 VDC continue to Test 2 If voltage is below 12 4 VDC charge battery and retest If battery will not hol...

Page 63: ...antifreeze DO NOT use antifreeze with stop leak additive s or put any other additives in cooling system Cooling System Maintenance and Service Maintenance Maintaining correct coolant level cleaning an...

Page 64: ...k condition of cooling system hoses clamps and associated components Replace as required 2 Fill with 2 0 L 2 1 U S qt equal parts of ethylene glycol anti freeze and water only Distilled or deionized w...

Page 65: ...moving and testing thermostat make sure all other possible causes such as debris accumulation obstruction leaks belt or fan failure coolant level and damaged components are eliminated as possible caus...

Page 66: ...4 15 psi 5 Observe system pressure on gauge Gauge Needle Holds Steady If gauge needle holds steady there should be no serious leaks in system It is however recommended that all connections be checked...

Page 67: ...tarts can cause severe injury or death Disconnect and ground spark plug lead s before servicing Clean all parts thoroughly as engine is disassembled Only clean parts can be accurately inspected and ga...

Page 68: ...tarter and Starter Plate NOTE Unless starter plate is damaged disassembly from crankcase is unnecessary 1 Disconnect leads attached to starter solenoid terminals 2 Remove screws securing starter to st...

Page 69: ...tor Mounting Bracket D Upper Radiator Hose E Ignition Coil F Mounting Bracket G E clip Retainer H Lower Radiator Hose I Radiator Assembly J Upper Radiator Support K Spacer L Air Cleaner Adapter Gasket...

Page 70: ...Disconnect breather hose from air cleaner adapter 3 Disconnect connector plug from rectifier regulator Remove screw securing rectifier regulator ground wire Rectifier regulator can remain secured to a...

Page 71: ...A E F I K G G J C H A Oil Sentry B Fan Mounting Bracket C Fan Shaft D Fan E Fan Belt F Fan Pulley G Ball Bearing H Retainer Ring I Bearing Carrier J Pulley Half K Spacer Shims L Pulley Adapter 2 Remov...

Page 72: ...er to remove flywheel from crankshaft Do not strike crankshaft or flywheel as these parts could become cracked or damaged 1 Use a flywheel strap wrench or holding tool to hold flywheel and loosen scre...

Page 73: ...nifold Separate housing and remove thermostat discard old gasket Unless fuel injectors are damaged or malfunctioning disassembly from intake manifold is unnecessary If replacement is required note pos...

Page 74: ...crankcase which transfer tube is connected to is sealed and installed at factory in a specific position Do not loosen remove or alter mounted position of this fitting at any time Contact factory serv...

Page 75: ...er NOTE Unless breather hose or breather hose insulator are damaged disassembly from breather cover is unnecessary 1 Remove screws securing breather cover to crankcase 2 Carefully pry under protruding...

Page 76: ...der Head Components B F G H I J K L M N C D O K E Q P C D F G H I J A A Valve B Head C Hydraulic Lifter D Push Rods E Head Gasket F Valve Stem Seal G Valve Spring Cap H Valve Spring I Valve Spring Ret...

Page 77: ...3 in piece from end of an old push rod and chuck it in a drill press 2 Lay a rag or shop towel on table of drill press and place lifter open end up on towel 3 Lower chucked push rod until it contacts...

Page 78: ...0 2751 in After cleaning check flatness of cylinder head and corresponding top surface of crankcase using a surface plate or piece of glass and feeler gauge Maximum allowable out of flatness is 0 076...

Page 79: ...erts are press fitted into cylinder head Inserts are not replaceable but can be reconditioned if not too badly pitted or distorted If cracked or badly warped cylinder head should be replaced Reconditi...

Page 80: ...ure plate to crankcase If a thick washer is installed under screw head in 10 location and or one silver ground screw is used normally No 4 or 6 position note these special assembly details for proper...

Page 81: ...n and Reassembly Disassembly 1 Remove screws 2 Lift oil pump assembly from closure plate Remove outer gerotor gear from closure plate 3 Ensure ball and spring remain installed in pressure relief hole...

Page 82: ...n ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion...

Page 83: ...k is up or dye colored stripe if contained is to left of end gap 3 Top compression ring top groove Install top ring using a piston ring expender Make sure identification mark is up or dye colored stri...

Page 84: ...ts that may collect in oil passages Use following procedure to remove and replace plug Remove Crankshaft Plug 1 Drill a 3 16 in hole through plug in crankshaft 2 Thread a 3 4 in or 1 in long self tapp...

Page 85: ...steep an angle will result in high oil consumption 4 After resizing check bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements These measure...

Page 86: ...operties of engine oil Check closure plate crankcase cylinder heads and valve covers to be certain that all old sealing material has been removed Use gasket remover lacquer thinner or paint remover to...

Page 87: ...x end caps and connecting rods NOTE Proper orientation of piston connecting rod assemblies inside engine is extremely important Improper orientation can cause extensive wear or damage NOTE Make sure t...

Page 88: ...375 0 83185 mm 0 03125 0 03275 in Yellow 0 84455 0 88265 mm 0 03325 0 03475 in Green 0 89535 0 99345 mm 0 03525 0 03675 in Gray 0 94615 0 98425 mm 0 03725 0 03875 in Black 0 99695 1 03505 mm 0 03925 0...

Page 89: ...hes 7 Install screws securing closure plate to crankcase If a thick flat washer was used on one of screws install it in number 10 location Install silver plated ground screw in its original location n...

Page 90: ...J A A Valve B Head C Hydraulic Lifter D Push Rods E Head Gasket F Valve Stem Seal G Valve Spring Cap H Valve Spring I Valve Spring Retainers J Valve Spring Keepers K Rocker Arms L Rocker Arm Pivot M R...

Page 91: ...Install lower mounting screws in 2 cover and finger tighten only Upper screws will be installed with air cleaner bracket Install Hydraulic Lifters NOTE Hydraulic lifters should always be installed in...

Page 92: ...pump Install clamp onto hose and position tangs of clamp parallel to those of first clamp 7 Holding pump assembly elevated assemble transfer tube to 90 fitting in crankcase as follows a For new first...

Page 93: ...ough 6 for other fuel injector Install Intake Manifold Assembly Torque Sequence 1 2 3 4 5 6 1 Check that gasket surfaces of intake manifold and cylinder heads are clean and free of any nicks or damage...

Page 94: ...angs of clamp point toward cylinder 1 away from fan Install Coolant By pass Hose If separated from intake manifold through individual component servicing 1 If connector fitting for by pass hose was re...

Page 95: ...keyway of crankshaft Make sure that key is properly seated and parallel with shaft 2 Thread starter mounting bolts into hub of flywheel or use flywheel puller to serve as a handle and set flywheel in...

Page 96: ...b into used holes in sequence shown 7 Install Oil Sentry switch into tapped breather port if removed earlier Apply pipe sealant with Teflon Loctite PST 592 Thread Sealant or equivalent to threads Torq...

Page 97: ...2 Install crankshaft pulley adapter onto flywheel hub so o set for pulley is out and holes are aligned Make sure adapter rests squarely on face of flywheel 3 Assemble front and rear pulley halves pla...

Page 98: ...ove belt and relocate a shim from between pulley halves to outside front Reinstall belt and recheck tension Repeat procedure until correct tension is reached If shims have all been moved to outside an...

Page 99: ...nents M E F B O I H A J D G G C E K L N A ECU B Relay C ECU Fuse Connector Mounting Bracket D Upper Radiator Hose E Ignition Coil F Mounting Bracket G E clip Retainer H Lower Radiator Hose I Radiator...

Page 100: ...ose clamps 2 Tighten radiator drain plug 3 Carefully set radiator assembly into place guiding lower radiator hose inside RH support bracket Make sure that cooling fins do not come in contact with fan...

Page 101: ...ugs are installed and torqued to specifications to prevent oil leakage 1 Install oil drain plug s Torque plug s to 13 6 N m 10 ft lb If oil drain valve is used make sure valve body is closed and cap i...

Page 102: ...amount weight and type of oil Refer to oil recommendations and procedures in Maintenance Specifications and Lubrication System 4 Turn on fuel supply Testing Engine and Setting Speed A A Idle Speed Adj...

Page 103: ...103 66 690 14 Rev A KohlerEngines com...

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