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Kohler Aegis LH775, Service Manual

The Kohler Aegis LH775 is a powerful and reliable engine designed for various applications. To ensure optimum performance and longevity, be sure to refer to the Service Manual available for free download at manualshive.com. This comprehensive manual provides detailed instructions for maintenance and troubleshooting.

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LH775
Service Manual

IMPORTANT:  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.

2

Safety

3

Maintenance

5

Speci

fi

 cations

11

Tools and Aids

14

Troubleshooting

18

Air Cleaner/Intake

19

Electronic Fuel Injection (EFI) System

45

Lubrication System

47

Electrical System

51

Starter System

55

Cooling System

59

Disassembly/Inspection and Service

75

Reassembly

66 690 07 Rev. --

KohlerEngines.com

1

Summary of Contents for Aegis LH775

Page 1: ...nsure engine is stopped and level before performing any maintenance or service 2 Safety 3 Maintenance 5 Specifications 11 Tools and Aids 14 Troubleshooting 18 Air Cleaner Intake 19 Electronic Fuel Inj...

Page 2: ...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 WARNING Cleaning Solvents can cause severe injury o...

Page 3: ...rs1 Change oil and oil filter Lubrication System Every 200 Hours Replace fuel filter Every 250 Hours1 Replace air cleaner element and check inner element Air Cleaner Intake Every 500 Hours1 Replace ai...

Page 4: ...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 Research Octane Number RON 90 octane mini...

Page 5: ...Inch Square Key 5 8 18 UNF Thread 7 16 20 Thread Option 120 96 4 762 Coolant Overflow Fill 39 00 1 535 Oil Fill 119 78 4 716 673 70 26 524 Overall Fuel Pump 440 00 17 323 2X 184 20 7 252 127 90 5 035...

Page 6: ...6 N m 10 ft lb Cylinder Head Cylinder Head Fastener torque in 2 increments first to 16 9 N m 150 in lb finally to 33 9 N m 300 in lb Rocker Pivot Fastener 11 3 N m 100 in lb 3 Values are in Metric un...

Page 7: ...in lb Ignition Spark Plug 27 N m 20 ft lb Ignition Module Fastener 6 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 Muffler Muffler Retainin...

Page 8: ...m 1 6156 in Crankshaft Bore in closure plate to Crankshaft Running Clearance New 0 039 0 087 mm 0 0015 0 0034 in Main Bearing Journals O D New O D Max Wear Limit Max Taper Max Out of Round 40 913 40 9...

Page 9: ...0070 in Top and Middle Compression Ring End Gap New Bore 0 250 0 56 mm 0 0098 0 022 in Used Bore Max 0 94 mm 0 037 in Piston Thrust Face O D 7 New 82 973 82 991 mm 3 2666 3 2673 in Max Wear Limit 82 8...

Page 10: ...nglish 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 Tig...

Page 11: ...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 Tester 120 V AC 60Hz...

Page 12: ...t 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 position while installing timing bel...

Page 13: ...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 14: ...to check simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are list...

Page 15: ...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 16: ...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 level in engine side is...

Page 17: ...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 flywheel...

Page 18: ...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 19: ...t parts or sparks from ignition Never use gasoline as a cleaning agent Explosive Fuel can cause fires and severe burns Do not fill fuel tank while engine is hot or running EFI System D C A B A P G O I...

Page 20: ...unused oxygen in exhaust indicating whether fuel mixture being delivered is rich or lean Based upon this feedback ECU further adjusts fuel input to re establish ideal air fuel ratio This operating mo...

Page 21: ...engine ECU requires a minimum of 7 0 volts to operate Adaptive memory in ECU is operational whenever required voltage is present however adapted values are lost if power supply is disrupted for any re...

Page 22: ...r fuel rail air baffle idle speed screw and air cleaner assembly Idle speed is only adjustment that may be performed on EFI system Standard idle speed setting for EFI engines is 1500 RPM but certain a...

Page 23: ...l Hold throttle closed and check resistance It should be 800 1200 a Turn key switch to ON RUN position Fuel pump will run for about three seconds and stop Turn switch off and back on to restart fuel p...

Page 24: ...imes every 2 seconds 5 Remove jumper wire or plug from service connector plug in wiring harness 6 Run engine at full throttle above 3000 RPM to warm up engine and initiate O2 sensor function in closed...

Page 25: ...ine ground Touch black lead at various points backtracking from engine ground back toward sensor watching for a voltage change at each location If correct voltage reading reappears at some point check...

Page 26: ...al times If at any time relay fails to activate circuit replace relay Electrical relay is used to supply power to injectors coils and fuel pump When key switch is turned ON and all safety switch requi...

Page 27: ...check resistance of each injector across two terminals Proper resistance is 12 20 If injector resistance is correct check whether connector and injector terminals are making a good connection If resis...

Page 28: ...tors is not recommended they should be replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem NOTE Do not ground coils with ignition ON as th...

Page 29: ...oblems and system errors than an actual component Battery Charging System EFI engines are equipped with either a 15 or 25 amp charging system to accommodate combined electrical demands of ignition sys...

Page 30: ...ped with rubber seals to prevent air leaks A throttle shaft repair kit is available to replace shaft if worn or damaged Appropriate TPS Initialization Procedure must be performed after any throttle sh...

Page 31: ...governor springs at this time 3 Insert a nail into hole in top of cross shaft Using light pressure rotate governor shaft counterclockwise as far as it will turn then torque hex nut on clamping screw...

Page 32: ...charged 12 volt battery with a minimum of 350 cold cranking amps is important in maintaining steady and reliable system operation Battery condition and state of charge should always be checked first...

Page 33: ...Used 8 Throttle Position Sensor TPS Input 9 Speed Sensor Input 10 Speed Sensor Ground 11 Not Used 12 High Temperature Warning Output 13 Not Used 14 Injector 1 Output 15 Injector 2 Output 16 Not Used 1...

Page 34: ...34 EFI System KohlerEngines com 66 690 07 Rev...

Page 35: ...es a diagnostic code in its fault memory If component or system returns to proper function ECU will eventually self clear fault code and turn off MIL If MIL stays illuminated it warns customer that de...

Page 36: ...Y 52 P0264 Injector 2 Short Circuit to Ground Y 52 P0265 Injector 2 Short Circuit to Battery Y 54 P0655 High Temperature Warning Lamp Circuit Open N 4 54 P1657 High Temperature Warning Lamp Circuit S...

Page 37: ...PS Fault Unrecognizable signal is being sent from sensor too high too low inconsistent Condition A limp home operating mode occurs with an overall decrease in operating performance and efficiency Fuel...

Page 38: ...If performance is pretty good problem is probably with oxygen sensor wiring or connectors If engine is still running rich laboring short on power or lean popping or misfiring fuel mixture is suspect...

Page 39: ...crankcase oil Blocked or restricted fuel return circuit to tank ECU Harness Related ECU to harness connection problem Code 34 Component Oxygen Sensor Fuel System Components Fault Long term fuel adapta...

Page 40: ...in harness ECU pin 18 to TPS pin 1 ECU pin 4 to TPS pin 2 ECU pin 8 to TPS pin 3 Throttle Body Related Throttle shaft inside TPS worn broken or damaged Throttle plate loose or misaligned Throttle plat...

Page 41: ...element shorted to ground Lamp missing Engine Wiring Harness Related Broken or shorted wire in harness ECU pin 29 to lamp open or shorted Vehicle Wiring Harness Related Broken or shorted wire in harne...

Page 42: ...42 EFI System KohlerEngines com 66 690 07 Rev Operate for an appropriate period of time based upon original fault codes...

Page 43: ...S Auto Learn Initialization Function Below Min Limit Code 44 TPS Auto Learn Initialization Function Above Max Limit Code 51 Injector 1 Code 52 Injector 2 Code 55 MIL Diagnostic Light Code 56 Pump Rela...

Page 44: ...les roughly Code 22 31 34 42 43 51 52 Vacuum intake air leak Fuel injector s fuel filter fuel line or fuel pick up dirty clogged restricted Insufficient fuel pressure delivery Engine Coolant Temperatu...

Page 45: ...ricating bearing surfaces lubrication system supplies oil to hydraulic valve lifters A high efficiency gerotor pump is located in closure plate Oil pump maintains high oil flow and oil pressure even a...

Page 46: ...allation 6 Fill crankcase with new oil Level should be at top of indicator on dipstick OIL SENTRY if equipped This switch is designed to prevent engine from starting in a low oil or no oil condition O...

Page 47: ...feeler gauge Adjust gap to 0 76 mm 0 03 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 ar...

Page 48: ...ase as temperatures decrease and battery capacity shrinks Refer to equipment s operating instructions for specific battery requirements Battery Size Recommendations Temperature Battery Required Above...

Page 49: ...ap Testing rectifier regulator may be performed as follows using appropriate rectifier regulator tester To test 25 amp rectifier regulators 1 Connect tester ground lead with spring clamp to body of re...

Page 50: ...y replace Test stator further using an ohmmeter steps 3 and 4 3 With engine stopped measure resistance across stator leads using an ohmmeter Condition Conclusion Resistance is 0 1 0 2 ohms Stator is O...

Page 51: ...ine starts and start switch is released starter solenoid is deactivated drive lever moves back and drive pinion moves out of mesh with ring gear into retracted position Troubleshooting Starting Diffic...

Page 52: ...utch housing and rotating pinion Pinion should rotate in only 1 direction Brushes and Springs Detail A A Wear Limit Length Inspect both springs and brushes for wear fatigue or damage Measure length of...

Page 53: ...nion outward on armature splines against retainer to help seat collar around retainer 3 Install offset thrust stop washer so smaller offset of washer faces retainer collar 4 Apply a small amount of oi...

Page 54: ...ly and 2 test leads 2 Connect 1 lead to flat spade S start terminal on solenoid Momentarily connect other lead to lower large post terminal When connection is made solenoid should energize audible cli...

Page 55: ...not exceed 70 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 le...

Page 56: ...dditive s or mix add other additives to cooling system Use only ethylene glycol antifreeze Cooling system capacity is approximately 2 liters 2 18 qt 1 Check condition of cooling system hoses clamps an...

Page 57: ...ving 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 causes...

Page 58: ...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 59: ...ter C Adapter Plate D Oil Drain Plug E Flywheel Cover F Radiator Drain Plug WARNING Before working on engine or equipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnect negative...

Page 60: ...uffler 1 Remove exhaust system muffler and attaching hardware from engine Remove Starter and Adapter Plate 1 Disconnect leads attached to starter solenoid terminals 2 Remove screws securing starter to...

Page 61: ...water pump 3 Remove screws securing two upper radiator supports to air cleaner mounting bracket 4 Carefully tilt pull radiator forward slightly to clear fan and lift complete assembly out of lower mou...

Page 62: ...lt J Bearing K Pulley L Pulley Half M Spacer Shims N Adapter 3 Tilt main bracket and disconnect choke linkage from choke lever Remove main control bracket 4 Unhook choke linkage from actuator lever on...

Page 63: ...ot necessary unless a problem exists see If disassembly is performed note assembly order and position of parts 1 Remove front nut and washer securing fan assembly to fan shaft Remove fan and pulley as...

Page 64: ...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 Remove screw an...

Page 65: ...water pump up and carefully work ferruled end of transfer tube out of fitting Remove water pump with transfer tube and hose section attached Remove and discard O ring from within channel of pump hous...

Page 66: ...until valves of one cylinder are closed Loosen rocker arm screws until rocker arms can be pivoted to free push rods 2 Remove push rods and mark their location as either intake or exhaust and cylinder...

Page 67: ...ing 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 mm 0 003 in Carefully...

Page 68: ...d if not too badly pitted or distorted If cracked or badly warped cylinder head should be replaced Recondition valve seat inserts following instructions provided with valve seat cutter being used Fina...

Page 69: ...le horizontal and pull it toward you to break RTV seal If necessary pry at bottom splitting tabs also Do not pry on sealing surfaces as this could cause leaks Carefully pull closure plate from crankca...

Page 70: ...ce is required refer to these following service procedures Disassembly 1 Remove screws 2 Remove oil pump assembly from closure plate 3 Remove oil pump rotor 4 Remove oil pickup by unhooking locking cl...

Page 71: ...lso lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn r...

Page 72: ...Must Be Completely Smooth Inspect gear teeth of crankshaft If teeth are badly worn chipped or some are missing replacement of crankshaft will be necessary Inspect crankshaft bearing surfaces for scor...

Page 73: ...r contaminated lubrication If cylinder bore is badly scored excessively worn tapered or out of round resizing is necessary Use an inside micrometer to determine amount of wear then select nearest suit...

Page 74: ...water and start again with more hot water and detergent Following scrubbing rinse cylinder with very hot clear water dry it completely and apply a light coating of engine oil to prevent rusting Measu...

Page 75: ...ropyl alcohol acetone lacquer thinner or electrical contact cleaner Install Flywheel End Oil Seal and Camshaft Oil Seal 1 Check to make sure that there are no nicks or burrs in crankshaft and camshaft...

Page 76: ...ston down into cylinder Be careful that oil ring rails do not spring free between bottom of ring compressor and top of cylinder 5 Guide lower end of connecting rod and rotate crankshaft to join two In...

Page 77: ...stick it onto thrust bearing Wipe some grease on face of original shim and stick it onto thrust washer Install closure plate onto crankcase without applying RTV sealant and secure it with only two or...

Page 78: ...l 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 normally numb...

Page 79: ...ls if they are deteriorated or damaged in any way Never reuse an old seal Assemble Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to lip of v...

Page 80: ...screws to 11 3 N m 100 in lb When tightening use a steady motion without interruption until proper torque is achieved Frictional heat from engaging threads may otherwise cause locking compound to set...

Page 81: ...ting in crankcase as follows a For new first time tube installation 1 Place a new ferrule compression ring in 90 fitting of crankcase and loosely install hex cap onto threads of fitting 2 Insert plain...

Page 82: ...long screw on each side Torque six intake manifold mounting screws in two steps first to 7 4 N m 66 in lb finally to 9 9 N m 88 in lb in sequence shown 4 Install and tighten pipe plug or temperature...

Page 83: ...in 3 o clock position Align mounting holes and install screws Torque each screw to 6 2 N m 55 in lb Install Flywheel CAUTION Damaging Crankshaft and Flywheel Can Cause Personal Injury Using improper p...

Page 84: ...reed retainer onto crankcase and secure with screw Hold assembly in line when tightening Torque screw to 3 9 N m 35 in lb 4 Install breather filter into cavity in crankcase 5 Carefully install breathe...

Page 85: ...D Governor Lever E Governor Spring 1 Install governor lever onto governor cross shaft If separated connect throttle link to governor lever with plastic bushing Hook dampening spring into small middle...

Page 86: ...ly work belt into place on pulleys Check belt tension There should be no more than 9 53 12 7 mm 3 8 1 2 belt deflection per side with 10 lbs of applied tension If belt tension is low remove belt and r...

Page 87: ...lace guiding lower radiator hose inside RH support bracket Make sure that cooling fins do not come in contact with fan blades as radiator is installed 4 Position upper radiator support brackets on top...

Page 88: ...ffler and mounting hardware Torque screws to 9 9 N m 88 in lb 2 Install nuts to exhaust studs Torque nuts to 24 4 N m 216 in lb Install Oil Filter and Fill Crankcase with Oil NOTE Make sure both oil d...

Page 89: ...89 66 690 07 Rev KohlerEngines com...

Page 90: ...90 KohlerEngines com 66 690 07 Rev...

Page 91: ...91 66 690 07 Rev KohlerEngines com...

Page 92: ...2011 by Kohler Co All rights reserved 92 KohlerEngines com 66 690 07 Rev...

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