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Command PRO CH440
Kohler Command PRO CH440
126 pages
Manual
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FORM NO.:
17 690 01 Rev
. D
ISSUED: 5/10
REVISED: 1/1
1
FOR SALES
AND SER
VICE INFORMA
TION
IN U.S.
AND CANADA, CALL
1-800-544-2444
KohlerEngines.com
ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044
© 201
1 by Kohler Co.
All rights reserved.
125
Table of Contents
Main Page
Table of Contents
3
Safety Precautions
5
Section 1. Safety and General Information
5
Engine Identification Numbers
7
Engine Identification Decal Location
7
Oil Recommendations
8
Fuel Recommendations
8
Oil Type
8
General Recommendations
8
Periodic Maintenance Instructions
9
Storage
9
Typical Engine Dimensions-CH270
10
Typical Engine Dimensions-CH270 with Low-Profi Le Air Cleaner
11
Typical Engine Dimensions-CH395
12
Typical Engine Dimensions-CH395 with Low-Profile Air Cleaner
13
Typical Engine Dimensions-CH440
14
Typical Engine Dimensions-CH440 with Low-Profi Le Air Cleaner
15
General Specifications
16
General Torque Values
24
Metric Fastener Torque Recommendations for Standard Applications
24
English Fastener Torque Recommendations for Standard Applications
25
Section 2. Tools & Aids
27
Rocker Arm/Crankshaft Tool
30
Engine Cranks but will Not Start
31
Engine Starts but Does Not Keep Running
31
Engine Starts Hard
31
Section 3. Troubleshooting
31
Engine Loses Power
32
Engine Knocks
32
Engine Overheats
32
External Engine Inspection
32
Cleaning the Engine
33
Basic Engine Tests
33
No Crankcase Vacuum/Pressure in Crankcase
33
Leakdown Test Results
34
Compression Test
34
Cylinder Leakdown Test
34
Leakdown Test Instructions
34
Service Precleaner
35
Quad-Clean
35
Section 4. Air Cleaner and Air Intake System
35
Normal Operation Position of Air Cleaner Cover
36
Cold Weather Operation Position of Air Cleaner Cover
36
Air Cleaner Cover Installation
36
Low-Profile Air Cleaner
37
Remove Screw and Cover
37
Remove Foam Element
38
Engine Shrouds
38
Fuel System Components
39
Maximum Fuel Level
39
Section 5. Fuel System and Governor
39
Fuel Type
40
Gasoline/Alcohol Blends
40
Gasoline/Ether Blends
40
Fuel Filters
40
Pick-Up Tube and Screen Orientation
41
Fuel Valve Cup, O-Ring, and Screen
41
Carburetor Cover Panel
41
Fuel System Tests
42
Troubleshooting – Fuel System Related Causes
42
High-Altitude Operation
43
Troubleshooting - Carburetor Related Causes
43
Adjusting Low Idle Speed
44
Carburetor Servicing
44
Removing Air Cleaner Assembly
44
Float, Inlet Needle, and Spring
45
Removing Float and Inlet Needle
45
Carburetor Gaskets
45
Main Jet Removal
46
Fuel Shut-Off Bowl, Screen, and O-Ring
46
Fuel Shut-Off Disc and Wave Washer
46
Fuel Shut-Off Lever
46
Carburetor Installation
47
Governor
47
Action of a Governor Gear
47
Typical Governor System
47
Governor Adjustment
48
Initial Adjustment
48
Oil Viscosity Grades Table
49
Oil Container Logo
49
Section 6. Lubrication System
49
Check Oil Level
50
Location of Dipstick, Oil Fill Plug, and Oil Drain Plugs
50
Location of Dipstick and Oil Fill Plug
50
Dipstick Oil Level Check
50
Oil Sentry
51
Oil Disposal
51
Change Oil
51
To Remove Starter
53
To Install Starter
53
Section 7. Retractable Starter
53
Rope Replacement
54
Removing Starter Handle
54
Left-Hand Knot
54
Installing Rope
54
Drive Plate and Pawl Details
55
Pawl (Dogs) Replacement
55
Handle Left-Hand Knot
55
Center Screw and Drive Plate
56
Oil Sentry Control System
57
Spark Plugs
57
Section 8. Electrical System and Components
57
Electronic Ignition System
59
Troubleshooting and Testing Ignition
59
Inductive Discharge Ignition System
59
Oil Sentry Function Check
61
Oil Sentry Continuity
61
Battery Charging Systems
62
Wiring Diagram, Retractable Starter
62
Wiring Diagram-3/4 Amp Charging System, Rectifi Ed Only
62
Stator
63
Rectifier-Regulator
63
Wiring Diagram-10/18 Amp Charging System, with Rectifier-Regulator
63
Amp Rectifier-Regulator
64
Troubleshooting Guide
64
Connections for Testing Charging Systems
64
Rectified Only (Non-Regulated) Systems
64
Battery
66
Electric Starting Motors
66
Starting Motor Precautions
66
Troubleshooting Guide – Starting Difficulties
66
Troubleshooting Guide - Electric Starting System
67
Disassembled Drive Components
68
Starter Drive Service
68
Starter Removal and Installation
68
Remove Housing and Drive End Cap Screws
68
Reinstall Dust Cover and Drive Pinion
69
Reinstall Drive End Cap
69
Reinstall Housing and Drive End Cap Screws
69
Typical Disassembly Sequence
71
Disconnect Spark Plug Lead
71
Turn Fuel Shut-Off Valve to off Position
71
Section 9. Disassembly
71
Remove Air Cleaner Assembly
72
Drain Oil from Crankcase
72
Remove Muffler and Heat Shield Assembly
72
Air Cleaner Base Removal
73
Remove Hex Nuts and Screw
73
Disconnect One End of Breather Hose
73
Carburetor Shroud Removal
73
Disconnecting Fuel Line
74
Fuel Tank Hex Screw Removal
74
Remove External Throttle, Governor and Choke Linkage
74
Remove Fuel Tank
74
Remove Carburetor
75
Remove Retractable Starter
75
Remove Blower Housing and Shields
75
Disconnect Oil Sentry System.
77
Fuel Tank Bracket Removal
77
Remove Control Panel Screws
77
Remove Electric Starter Screws
77
Remove Cylinder Head Mounting Screws
78
Valve Cover Removal
78
Remove Valves
78
Rocker Arm Removal
78
Remove Ignition Module
79
Remove Flywheel
79
Removing Flywheel Nut Using Strap Wrench
80
Remove Stator
80
Remove Closure Plate
81
Remove Balance Shaft
81
Remove Oil Sentry
82
Remove Piston, Connecting Rod and Crankshaft
82
Remove Camshaft and Valve Tappets
82
Remove Governor Assembly
83
CH270 Governor Gear Assembly
83
CH395 Governor Gear Assembly
83
CH395 Governor Assembly Components
84
CH440 Governor Gear Assembly
84
Pry Governor Gear to Remove
84
CH440 Governor Assembly Components
84
Removing Crankcase Crankshaft Bearing
85
Removing Governor Cross Shaft Hitch Pin
85
Removing Crankcase Seal
85
Remove Crankcase and Closure Plate Seals and Bearings
85
Automatic Compression Release (ACR)
87
ACR Operation Details
87
Section 10. Inspection and Reconditioning
87
Cam Lobe Checking a
88
CH270 Cam Lobe Dimension
88
Camshaft and Tappet Inspection Points
88
Camshaft & Tappets
88
Crankshaft
89
CH440 Cam Lobe Dimension a
89
Cam Lobe Checking B
89
Cam Lobe Dimension B
89
Crankcase
90
Honing
90
Measuring Cylinder Bore
90
Flywheel
91
Measuring Piston-To-Bore Clearance
91
Measuring Piston Diameter
91
Clean Cylinder Bore after Honing
91
Cylinder Head and Valves
92
CH395 Valve Specifications
92
CH440 Valve Specifications
92
CH270 Valve Specifications
92
Normal
93
Bad Condition
93
Leakage
93
Coking
93
Valve Guides
94
Excessive Combustion Temperatures
94
Gum
94
Stem Corrosion
94
Valve Stem Seals
95
Pistons and Rings
95
Lapping Valves
95
Valve Seat Inserts
95
Overheated or Deteriorated Oil
96
Common Types of Piston Damage
96
Abrasive Scratched Rings
96
Stuck, Broken Rings
96
Install New Piston Rings
97
Measuring Piston Ring End Gap
97
Measuring Piston Ring Side Clearance
97
Piston Ring Positions
97
Connecting Rods
98
Closure Plate Assembly
98
Governor Assembly (Internal)
98
Piston Ring Expander
98
Typical Reassembly Sequence
99
Install Crankcase Bearings and Oil Seals
99
Installing Crankcase Main Bearing
99
Section 11. Reassembly
99
Install Closure Plate Oil Seal
100
Governor Gear Assembly
100
Closure Plate Oil Seal Installation Depth
100
Install Governor Assembly
100
Installing Governor Gear Assembly
101
Installing Thrust Washer and Hitch Pin
101
Install Governor Gear Assembly
101
Installing Governor Shaft
101
Install Governor Gear Shaft
102
Install Governor Gear
102
Install Oil Sentry System
103
Install Crankshaft
103
Oil Sentry Float Switch Mounting
103
Install Connecting Rod with Piston and Rings
104
Piston/Connecting Rod Orientation
104
Connecting Rod Details
104
Piston Ring Orientation
104
Rod Dipper Orientation
105
Connecting Rod Match Marks
105
Install Valve Tappets and Camshaft
105
Install Balance Shaft
105
Install Closure Plate
106
Install Stator
107
Install Flywheel
107
Stator Screws Torque Sequence
107
Install Bracket and Torque Screw
107
Crankshaft Flywheel Key Position
108
Install Flywheel Shield
108
Install Drive Cup
108
Install Flywheel Fan
108
Install Ignition Module
109
Torque Flywheel Nut
109
Setting Ignition Module Air Gap
109
Assemble Cylinder Head
110
Install Cylinder Head
110
Connect Kill Wire to Module
110
Installing Valve Retainers
110
Installing Push Rods
111
Installing Rocker Arms, Adjusters and Locknuts
111
Install Push Rods and Rocker Arms
111
Cylinder Head Screws Torquing Sequence
111
Install Fuel Tank Supports and Shut down Switch with Bracket
112
Install Valve Cover
112
Lock Valve Tappet Adjustment
112
Installing and Torquing New Spark Plug
112
Install Fuel Tank Bracket
113
Install Carburetor Throttle Link
113
Install Engine Shields and Air Cleaner Base
113
Install Carburetor
113
Position Upper Shield
114
Upper Shield Hardware
114
Air Cleaner Base Installation
114
Cylinder Heat Shield Mounting Bolt Location
114
Install Electric Starter and Control Panel
115
Install Upper Heat Shield
115
Install Lower Heat Shield
115
Align and Mount Starter
115
Spark Plug Wire Routing
116
Install Retractable Starter
116
Install Blower Housing
116
Install Throttle Link, Governor Lever, Governor Spring/Throttle Lever
117
Governor Lever Installation
117
Governor Lever Adjustment
117
Install Throttle Lever for CH270
117
Governor Lever and Hole Position/Rpm Chart
118
Throttle Lever Hardware
118
Torque Side Strap Screw
120
Reconnect Electrical Leads
120
Install Fuel Tank
120
Install Oil Sentry
120
Install Carburetor Cover
121
Install Muffler and Heat Shield Assembly
121
Install Air Cleaner Element and Cover
122
Install the Quad-Clean Air Cleaner
122
Install the Low-Profile Air Cleaner
122
Prepare the Engine for Operation
122
Low Idle Speed Adjustment Screw
123
High Speed Stop Screw
123
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