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.
2
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.
3
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).
4
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.
5
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
4
1
3
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.
6
Specifications
KohlerEngines.com 14 690 10 Rev. --
TORQUE SEQUENCES HD675 HD775
HD675 Oil Pan Fasteners
1
6
4
5
7
3
2
HD775 Oil Pan Fasteners
1
6
4
5
3
2
Valve Cover Fasteners
2
4
1
3
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.
7
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.
8
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.
9
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.)
0.025 mm (0.0009 in.)
24.975/24.989 mm
(0.9832/0.9838 in.)
0.025 mm (0.0009 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.)
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.)
0.010 mm (0.0004 in.)
29.985/29.995 mm
(1.1805/1.1809 in.)
0.010 mm (0.0004 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.)
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.
10
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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