Kohler HD Series Manual de usuario

114 690 10 Rev. -- KohlerEngines.com

HD675, HD775

Service Manual

2 Safety

3 Maintenance

5 Speciﬁcations

12 Tools and Aids

15 Troubleshooting

20 Air Cleaner/Intake

21 Fuel System

28 Governor System

30 Lubrication System

32 Electrical System

38 Starter System

42 Disassembly/Inspection and Service

55 Reassembly

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.

Safety

KohlerEngines.com 14 690 10 Rev. --

SAFETY 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 damage.

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

WARNING

Explosive Fuel can cause

ﬁres and severe burns.

Do not ﬁll 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

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.

WARNING

Rotating Parts can cause

severe injury.

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.

WARNING

Carbon Monoxide can

cause severe nausea,

fainting or death.

Avoid inhaling exhaust

fumes. Never run engine

indoors or in enclosed

spaces.

Engine exhaust gases contain

poisonous carbon monoxide.

Carbon monoxide is odorless,

colorless, and can cause death if

inhaled.

WARNING

Accidental Starts can

cause severe injury or

death.

Disconnect and ground

spark plug lead(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 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 or

death.

Use only in well

ventilated areas away

from ignition sources.

Carburetor cleaners and solvents

are extremely ﬂammable. Follow

cleaner manufacturer’s warnings

and instructions on its proper and

safe use. Never use gasoline as a

cleaning agent.

CAUTION

Electrical Shock can

cause injury.

Do not touch wires while

engine is running.

CAUTION

Damaging 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 ﬂywheel.

WARNING

Uncoiling Spring can

cause severe injury.

Wear safety goggles or

face protection when

servicing retractable

starter.

Retractable starters contain a

powerful, recoil spring that is

under tension. Always wear safety

goggles when servicing retractable

starters and carefully follow

instructions in Retractable Starter

for relieving spring tension.

Maintenance

14 690 10 Rev. -- KohlerEngines.com

MAINTENANCE INSTRUCTIONS

WARNING

Before working on engine or equipment, disable engine as

follows: 1) Disconnect spark plug lead(s). 2) Disconnect

negative (–) battery cable from battery.

Accidental Starts can cause severe injury or

death.

Disconnect and ground spark 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.

MAINTENANCE SCHEDULE

Before every Use

●Check oil level. Add oil if low. Do not overﬁll. Lubrication System

●Check air cleaner for dirty, loose, or damaged parts. Air Cleaner/Intake

●Check precleaner for dirty or torn material. Air Cleaner/Intake

After ﬁrst 3-5 Hours (approximately 3rd to 5th use)

●Change oil. Lubrication System

Every 25 Hours or Annually¹

●Service/replace precleaner. Air Cleaner/Intake

Every 50 Hours or Annually¹

●Change oil. Lubrication System

●Replace air cleaner element. Air Cleaner/Intake

●Replace fuel ﬁlter (if equipped).

Every 100 Hours or Annually¹

●Clean spark arrestor (if equipped).

Every 125 Hours or Annually¹

●Replace spark plug and set gap. Electrical System

1Perform these procedures more frequently under severe, dusty, dirty conditions.

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁnd a local Kohler authorized

dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Maintenance

KohlerEngines.com 14 690 10 Rev. --

OIL RECOMMENDATIONS

We 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

WARNING

Explosive Fuel can cause ﬁres and severe

burns.

Do not ﬁll 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 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.

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 overﬁll fuel tank.

●Do not use gasoline older than 30 days.

STORAGE

If engine will be out of service for 2 months or more

follow procedure below.

1. 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 oil.

3. Disconnect battery or negative (-) battery cable (if

equipped).

4. Store engine in a clean, dry place.

Speciﬁcations

14 690 10 Rev. -- KohlerEngines.com

ENGINE IDENTIFICATION NUMBERS

Kohler engine identiﬁcation numbers (model, speciﬁcation and serial) should be referenced for eﬃcient repair,

ordering correct parts, and engine replacement.

Model. . . . . . . . . . . . . . . . . . . . . HD675

HD Series Engine

Vertical Shaft

Numerical Designation

Speciﬁcation . . . . . . . . . . . . . . . HD675-3000

Serial . . . . . . . . . . . . . . . . . . . . . 4823500328

Year Manufactured Code Factory Code

Code Year

48 2018

49 2019

50 2020

GENERAL SPECIFICATIONS2,4 HD675 HD775

Bore 65 mm (2.6 in.) 70 mm (2.8 in.)

Stroke 45 mm (1.8 in.)

Displacement 149 cc (9.1 cu. in.) 173 cc (10.6 cu. in.)

Oil Capacity (reﬁll) 0.6 L (20 oz.)

Maximum Angle of Operation (@ full oil level)320°

TORQUE SEQUENCES HD675 HD775

(Refer to Torque Speciﬁcations for torque values.)

Cylinder Head Fasteners

2 Values are in Metric units. Values in parentheses are English equivalents.

3Exceeding maximum angle of operation may cause engine damage from insuﬃcient lubrication.

4Any and 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.

Speciﬁcations

KohlerEngines.com 14 690 10 Rev. --

TORQUE SEQUENCES HD675 HD775

HD675 Oil Pan Fasteners

HD775 Oil Pan Fasteners

Valve Cover Fasteners

TORQUE SPECIFICATIONS2,5 HD675 HD775

Air Cleaner Base

Stud Fastener 8 N·m (71 in. lb.)

Crankcase Fastener 8 N·m (71 in. lb.)

Blower Housing

Stud 10 N·m (89 in. lb.)

Nut 8 N·m (71 in. lb.)

2 Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

14 690 10 Rev. -- KohlerEngines.com

TORQUE SPECIFICATIONS2,5 HD675 HD775

Brake (if equipped)

Mounting Fastener 9.5 N·m (84 in. lb.)

Breather Cover

Fastener 10 N·m (89 in. lb.)

Carburetor

Stud Fastener 8 N·m (71 in. lb.)

Stud 5 N·m (44 in. lb.)

Auto Choke Arm Assembly Nut (if equipped) 8.5 N·m (75 in. lb.)

Auto Choke Arm Assembly Screw (if equipped) 2.3 N·m (20 in. lb.)

Connecting Rod

Cap Fastener (torque in increments) 12.5 N·m (110 in. lb.)

Cylinder Head (torque sequence on page 5 )

Fastener (torque in 2 increments) ﬁrst to 14 N·m (123 in. lb.)

ﬁnally to 27.8 N·m (246 in. lb.)

Dipstick Tube (if equipped)

Fastener 8 N·m (71 in. lb.)

Electric Starter (if equipped)

Fastener 9.5 N·m (84 in. lb.)

Finger Guard (as equipped)

Fastener (Muﬄer Side, Carburetor Side) 9.5 N·m (84 in. lb.)

Flywheel

Retaining Nut 51.5 N·m (38 ft. lb.)

Fuel Pump (if equipped)

Pump to Bracket Fastener 2.3 N·m (20 in. lb.)

Stud (into crankcase) 10 N·m (89 in. lb.)

Lock Nut (Bracket to Studs) 8 N·m (71 in. lb.)

Fuel Tank

Stud 10 N·m (71 in. lb.)

Lower Tank Bracket to Crankcase Screw 8 N·m (71 in. lb.)

Governor

Lever Fastener 9.5 N·m (84 in. lb.)

Gear Fastener 9.5 N·m (84 in. lb.)

Ignition

Spark Plug 27 N·m (20 ft. lb.)

Module Fastener (Stud or Screw) 10 N·m (89 in. lb.)

Stator Screw (if equipped) 9.5 N·m (84 in. lb.)

2 Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

Speciﬁcations

KohlerEngines.com 14 690 10 Rev. --

TORQUE SPECIFICATIONS2,5 HD675 HD775

Muﬄer

Exhaust Stud 5.0 N·m (44 in. lb.)

Lock Nut 9.5 N·m (84 in. lb.)

Shoulder Screw 9.5 N·m (84 in. lb.)

Oil Pan (torque sequence on page 6 )

Oil Drain Plug613.6 N·m (120 in. lb.)

Fastener 11.0 N·m (98 in. lb.) 14.7 N·m (130 in. lb.)

Retractable Starter

Fastener 8 N·m (71 in. lb.)

Rocker Arm

Stud 13.6 N·m (120 in. lb.)

Pivot Jam Nut 9.5 N·m (84 in. lb.)

Speed Control

Bracket Assembly Fastener 8 N·m (71 in. lb.)

Valve Cover (torque sequence on page 6 )

Fastener 8 N·m (71 in. lb.)

CLEARANCE SPECIFICATIONS2HD675 HD775

Camshaft

End Play 0.3/0.85 mm (0.0118/0.0335 in.)

Running Clearance 0.013/0.0555 mm (0.00051/0.00217 in.)

Connecting Rod

Connecting Rod-to-Crankpin Running Clearance

New 0.025/0.045 mm (0.0009/0.0017 in.)

Connecting Rod-to-Crankpin Side Clearance

New 0.03/0.48 mm

(0.00118/0.0189 in.)

0.13/0.58 mm

(0.0051/0.0228 in.)

Connecting Rod-to-Piston Pin Running Clearance 0.008/0.025 mm (0.0003/0.0009 in.)

Piston Pin End I.D. New @ 21°C (70°F) 13.006/13.017 mm

(0.5120/0.5125 in.)

18.006/18.017 mm

(0.7088/0.7093 in.)

Crankcase

Governor Cross Shaft Bore I.D.

New 6.000/6.024 mm (0.2362/0.2372 in.)

2Values are in Metric units. Values in parentheses are English equivalents.

5Lubricate threads with engine oil prior to assembly.

6Apply thread sealant around three full threads before assembly. No excess sealant allowed on inside or outside of

joint. Threads with preapplied sealant do not require use of additional sealant. Approved sealants include Perma-Loc

LH 150, Perma-Loc MM 115, Perma-Loc HH 120, Perma-Loc HL 126.

Speciﬁcations

14 690 10 Rev. -- KohlerEngines.com

CLEARANCE SPECIFICATIONS2HD675 HD775

Crankshaft

End Play (free) 0.427/1.298 mm (0.0168/0.05110 in.)

Bore in Oil Pan I.D. 27.050/27.071 mm (1.06496/1.06578 in.)

Bore in Oil Pan Running Clearance 0.008/0.121 mm (0.0031/0.00476 in.)

Bearing (ﬂywheel) Journal O.D.

Max. Taper

Max. Out-of-Round

25.005/25.019 mm

(0.9844/0.9850 in.)

0.025 mm (0.0009 in.)

24.975/24.989 mm

(0.9832/0.9838 in.)

0.025 mm (0.0009 in.)

Bearing (PTO) Journal O.D.

Max. Taper

Max. Out-of-Round

26.95/26.97 mm (1.061/1.062 in.)

0.025 mm (0.0009 in.)

Connecting Rod Journal O.D.

New

Max. Taper

Max. Out-of-Round

25.985/25.995 mm

(1.0230/1.0234 in.)

0.010 mm (0.0004 in.)

29.985/29.995 mm

(1.1805/1.1809 in.)

0.010 mm (0.0004 in.)

Cylinder Bore

Bore I.D. 65.00/65.02 mm

(2.559/2.560 in.)

70.00/70.02 mm

(2.755/2.756 in.)

Max. Out-of-Round

Max. Taper

0.0127 mm (0.0005 in.)

Cylinder Head

Max. Out-of-Flatness 0.08 mm (0.003 in.)

Governor

Governor Cross Shaft -to-Crankcase Running Clearance 0.020/0.064 mm (0.0007/0.0025 in.)

Cross Shaft O.D.

New 5.96/5.98 mm (0.2346/0.2354 in.)

Gear Shaft O.D.

New 6.01/6.03 mm (0.2366/0.2374 in.)

Governor Gear Shaft-to-Governor Gear Running Clearance 0.09/0.19 mm (0.0035/0.0074 in.)

Ignition

Spark Plug Gap 0.76 mm (0.030 in.)

Module Air Gap 0.254 mm (0.010 in.)

2 Values are in Metric units. Values in parentheses are English equivalents.

Speciﬁcations

KohlerEngines.com 14 690 10 Rev. --

CLEARANCE SPECIFICATIONS2HD675 HD775

Piston, Piston Rings, and Piston Pin

Pin Bore I.D. 13.002/13.008 mm

(0.5118/0.5121 in.)

18.000/18.008 mm

(0.7086/0.7089 in.)

Pin O.D. 12.990/12.996 mm

(0.5114/0.5116 in.)

17.990/17.996 mm

(0.7082/0.7085 in.)

Top and Center Compression Ring Side Clearance

New Bore 0.001/0.020 mm (0.00004/0.00080 in.)

Top and Center Compression Ring End Gap

New Bore

Top

Center

0.1/0.25 mm

(0.0039/0.0098 in.)

0.61/0.76 mm

(0.0240/0.0299 in.)

0.1/0.25 mm

(0.0039/0.0098 in.)

0.3/0.5 mm

(0.0118/0.0197 in.)

Thrust Face O.D. 64.975/64.985 mm

(0.2558/0.2558 in.)

69.960/69.980 mm

(2.7543/2.7551 in.)

Piston Thrust Face-to-Cylinder Bore Running Clearance 0.025/0.035 mm

(0.0010/0.0014 in.)

0.020/0.060 mm

(0.0007/0.0024 in.)

Valves and Valve Lifters

Intake and Exhaust Valve Lash 0.0762/0.127 mm (0.003/0.005 in.)

Intake Valve Stem-to-Valve Guide Running Clearance 0.020/0.047 mm (0.0007/0.0018 in.)

Exhaust Valve Stem-to-Valve Guide Running Clearance 0.055/0.082 mm (0.0021/0.0032 in.)

Intake Valve Guide I.D. 5.500/5.512 mm (0.2165/0.2170 in.)

Intake Valve Stem Diameter 5.465/5.480 mm (0.2151/0.2157 in.)

Exhaust Valve Guide I.D. 5.500/5.512 mm (0.2165/0.2170 in.)

Exhaust Valve Stem Diameter 5.430/5.445 mm (0.2137/0.2143 in.)

Nominal Valve Face Angle 25°, 45°, 60°

2 Values are in Metric units. Values in parentheses are English equivalents.

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