Kohler LH775 Engine

Tools: Tachometer

1. Park on level surface and engage parking brake.
2. Raise or remove cargo bed; install bed safety support.
3. Start engine and reach operating temperature.
4. At low idle, check engine operates at 1300 + 50 RPM; adjust idle speed screw if incorrect.
5. Increase to high idle by fully depressing accelerator pedal; check 3600 + 50 RPM.
6. If high idle incorrect, loosen jam nut, adjust high speed screw, tighten jam nut.
7. Check accelerator pedal clearance 0.200 to 0.350 in (5.1 to 8.9 mm) at full depression; adjust cable jam nuts if needed.
8. Recheck low and high idle after adjustments.
9. Lower or install cargo bed.

1. Rotate steering wheel to center the pitman arm.
2. Measure center-to-center distance between front wheels at front and rear; measurements should be equal within 0.120 in (3 mm).
3. Rotate tires 90 degrees and make a second measurement.
4. If adjustment needed, loosen jam nuts on tie rod ends and rotate tie rods equally.
5. Torque jam nuts 45 to 55 ft-lb (61 to 74 N-m).
6. Check for component interference through lock-to-lock steering.

1. Park on level surface, shut engine off and remove key.
2. Remove brake lever handle; loosen set screw on parking brake lever knob.
3. Adjust parking brake with knob until a force of 45 to 50 lb (20 to 22 kg) actuates the brake lever.
4. Tighten set screw to secure adjustment and install brake lever handle.

⚠ Failure to use gauge with recommended pressure rating could result in damage or injury.

Tools: Hydraulic pressure test kit (TOR47009), Hydraulic tester (TOR214678), Phototac

1. Operate vehicle approximately 10 minutes to reach normal oil temperature.
2. Park on level surface, raise/support bed, shut engine off, relieve system pressure.
3. Disconnect pressure hose from gear pump; install tester with gauges and flow meter in series.
4. Start engine and run at low idle; check for leaks.
5. Fully depress accelerator pedal; verify engine speed is 3600 RPM.
6. Slowly close flow control valve until 1500 PSI (103 bar); record flow.
7. Good pump flow approximately 4.5 GPM (17.0 LPM) at 1500 PSI.
8. If flow less than 3.8 GPM or 1500 PSI cannot be obtained, inspect pump suction line and pump.
9. To test relief pressure, turn steering wheel to full lock momentarily; system pressure should be approximately 1800 PSI (124 bar).
10. Remove tester and reinstall hose.

Tools: Steel plug with O-ring seal

1. Shut off engine and engage parking brake.
2. Remove all pressure from lift cylinder by fully retracting it (lift lever in LOWER position).
3. Disconnect hydraulic hose from base end of cylinder; install steel plug with O-ring seal in hose; clean cylinder port.
4. Start engine and apply pressure to rod end of cylinder (LOWER position).
5. If any oil comes out of open cylinder port, cylinder has internal leak; repair or replace.
6. Reconnect hose when complete; repeat for second lift cylinder if necessary.

⚠ Do not turn steering wheel to the left (counterclockwise) as system damage may occur.

⚠ Keep body and hands away from disconnected hoses that might eject fluid under pressure.

1. Reach normal operating temperature.
2. Perform gear pump flow and system relief pressure tests first.
3. Drive slowly in a figure eight on level surface; no shaking or vibration allowed.
4. Turn steering wheel with small quick movements; let go; wheel should not continue to turn.
5. To test cylinder, extend rod fully, turn engine off, remove hose from rod end fitting and plug hose.
6. With engine off, turn wheel right; if oil comes out of open fitting, cylinder has internal leakage.
7. Reconnect hose; if problem persists and pump/relief are acceptable, service steering control valve.

⚠ After servicing brakes, always check brakes in a wide open, level area.

Tools: Transparent hose

1. Remove hood to access brake master cylinder; check fluid level; use DOT 3 brake fluid.
2. Connect transparent hose to bleeder valve on left rear caliper; submerge end in clean brake fluid.
3. Have second person pump brake pedal several times then hold down firmly.
4. Open bleeder valve until pedal fades to floor, then close.
5. Repeat until continuous flow with no air bubbles; maintain reservoir level.
6. Torque bleeder valve 54 to 66 in-lb (6.2 to 7.4 N-m).
7. Repeat for right rear, left front and right front calipers.
8. Install hood and test brakes.

⚠ Use DOT 3 brake fluid in the speed control system.

1. Park on level surface, shut engine off, remove key and apply parking brake.
2. Remove knobs from speed range and hydraulic lift levers.
3. Remove six washer head screws securing control plate; lift to access speed control reservoir.
4. Move speed range lever between all positions (A to D and T) three or four times.
5. Make sure fluid level in reservoir is correct; use DOT 3 brake fluid.
6. Install control plate and secure with six screws; install knobs.

⚠ Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel.

1. Install wheel and secure with five lug nuts.
2. Lower vehicle to ground.
3. Tighten lug nuts in a star pattern in two steps.
4. First tighten all lug nuts to 40 ft-lb (55 N-m).
5. Then torque all lug nuts to 80 to 90 ft-lb (109 to 122 N-m).

⚠ Use eye protection when using compressed air.

Tools: Brake cleaner

1. Remove two bolts securing caliper assembly.
2. Remove caliper anvil and slide brake pads from pins on bracket.
3. Slide caliper body from caliper bracket.
4. Remove pistons; remove and discard O-rings, dust seals and square seals.
5. Clean components with brake cleaner.
6. Check pads; replace if friction material worn to less than 1/16 in (1.6 mm).
7. Lubricate seals and pistons with BAF-12 lube and install into caliper body.
8. Install dust seals and lubricate O-rings with white lithium grease.
9. Slide caliper body onto pins, install pads and caliper anvil; torque bolts 27 to 33 ft-lb (37 to 44 N-m).

⚠ Components may be hot; allow to cool before working.

Tools: 1 in open end wrench

1. Park on level surface, raise/support bed, shut engine off, engage parking brake, remove key.
2. Remove CVT enclosure cover.
3. Use 1 in open end wrench in secondary clutch opening to pry sheaves apart.
4. Remove drive belt from primary clutch then secondary clutch.
5. To install, pry secondary clutch sheaves apart and place belt between them.
6. Route drive belt onto primary clutch and remove wrench.
7. Check belt is centered between sheaves of both clutches.
8. Install CVT enclosure cover and lower bed.

⚠ Do not lubricate clutch components during assembly.

1. Remove lock nut from each shoulder screw; discard lock nuts.
2. Slide shoulder screws out and remove clutch weights.
3. Clean all dust and debris from components.
4. Inspect crankshaft and stationary sheave tapers; replace if severely damaged.
5. Check clutch weight contact surfaces; replace all three as a set if worn.
6. Position weights to moveable sheave and slide shoulder screws in with threads clockwise.
7. Install new lock nuts and torque 40 to 50 in-lb (4.6 to 5.6 N-m).