Kohler Command PRO CH270 Service Manual
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Kohler Command PRO CH270 Service Manual

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S
M
ERVICE
ANUAL
H
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ORIZONTAL
RANKSHAFT
CH270
CH395
CH440

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Summary of Contents for Kohler Command PRO CH270

  • Page 1 ERVICE ANUAL ORIZONTAL RANKSHAFT CH270 CH395 CH440...

  • Page 3: Table Of Contents

    Contents Section 1. Safety and General Information................Section 2. Tools & Aids......................Section 3. Troubleshooting....................... Section 4. Air Cleaner and Air Intake System................Section 5. Fuel System and Governor..................Section 6. Lubrication System....................Section 7. Retractable Starter....................Section 8. Electrical System and Components............... Section 9.

  • Page 5: Section 1. Safety And General Information

    Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.
  • Page 6 Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause fi res and Explosive Fuel can cause fi res and Carbon Monoxide can cause severe burns. severe nausea, fainting or death. severe acid burns. Do not fi ll the fuel tank while the Avoid inhaling exhaust fumes, and Charge battery only in a well ventilated engine is hot or running.
  • Page 7 Section 1 Safety and General Information Engine Identifi cation Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specifi cation, and Serial Numbers, including lett er suffi xes if there are any. The engine identifi cation numbers appear on a decal, or decals, affi...
  • Page 8 Gasoline/Alcohol blends 10W -30 Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted.
  • Page 9 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) batt ery cable from batt ery. Maintenance Schedule 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 service center. Frequency...
  • Page 10 Section 1 Safety and General Information Dimensions in millimeters. G A S C AP Inch equivalents shown in ( ). R E M O VA L 1 06 .00 A IR C LE A N ER 12 .50 37 3 .5 3 (4.1 73 ) C O VE R R E M O VAL (0 .4 9 2)
  • Page 11 Section 1 Safety and General Information 2 6 5.7 0 [1 0 .4 6 1] Dimensions in millimeters. Inch equivalents shown in ( ). 26 0.3 8 2 61 .29 [10 .25 1] [1 0.2 87 ] 32 3.4 5 3 2 2.61 [12 .73 4] [1 2 .7 01 ]...
  • Page 12 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in ( ). SECONDARY 3.75 MOUNTING FACE [0.148] 344.57 PRIMARY [13.566] MOUNTING 117.67 FACE [4.633] CLEANER 27.33 COVER 30.20 [1.076] REMOVAL 402.84 [1.189] [15.860] CENTER GRAVITY 58.31 [2.296] 147.11 1 IN.
  • Page 13 Section 1 Safety and General Information 2 8 9.1 9 Dimensions in millimeters. [11.3 8 5 ] Inch equivalents shown in ( ). 2 9 1 .2 8 2 89 .8 8 [11 .4 6 8 ] [11 .4 1 3] 37 8 .4 0 37 9 .8 0 [14 .8 9 8]...
  • Page 14 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in ( ). 4 11 .13 [16 .1 8 6] Ø 1 3 1 7 .2 2 3 2 3 .5 9 S T R A IG H T [1 2 .49 ] [1 2 .7 4 ] P TO...
  • Page 15 Section 1 Safety and General Information 3 05 .66 Dimensions in millimeters. [1 2.0 34 ] Inch equivalents shown in ( ). 3 1 7.22 2 99 .6 8 [1 2 .4 89 ] [11.79 9 ] 4 04 .76 3 87 .22 [1 5.9 36 ] [1 5.2 45 ]...
  • Page 16 Section 1 Safety and General Information General Specifi cations Gross Power (@ 3600 RPM, exceeds SAE J1940 HP Standards) Gross Power (@ 3600 RPM, exceeds SAE J1940 HP Standards) C CH270 ......................5.2 kW (7.0 HP) CH395 ......................7.1 kW (9.5 HP) CH440 ......................
  • Page 17 Section 1 Safety and General Information Blower Housing and Sheet Metal M6 Shoulder Screw Torque ................10 N·m (89 in. lb.) M6 Nut Torque ....................8.0 N·m (71 in. lb.) Camshaft Running Clearance CH270 ......................0.007/0.043 mm (0.0003/0.0017 in.) CH395,CH440 ................... 0.016/0.052 mm (0.0006/0.0020 in.) Bore I.D.
  • Page 18 Section 1 Safety and General Information Connecting Rod Connecting Rod Screw Torque (torque in increments) CH270 ......................12 N·m (106 in. lb.) CH395,CH440 ................... 20 N·m (177 in. lb.) Crankpin End I.D. @ 21°C (70°F) CH270 ....................30.021/30.026 mm (1.1819/1.1821 in.) CH395,CH440 ..................
  • Page 19 Section 1 Safety and General Information Ball Bearing Internal Clearance CH270 ......................0.003/0.025 mm (0.0001/0.0010 in.) CH395 ......................0.005/0.020 mm (0.0002/0.0008 in.) CH440 ......................0.006/0.020 mm (0.0002/0.0008 in.) Crankshaft O.D. (New) CH270 ......................24.975/24.989 mm (0.9833/0.9838 in.) CH395 ......................29.975/29.989 mm (1.1801/1.1807 in.) CH440 ......................
  • Page 20 Section 1 Safety and General Information Flywheel Flywheel Retaining Nut Torque CH270 ......................74 N·m (655 in. lb.) CH395,CH440 ................... 113 N·m (1000 in. lb.) Fuel Tank Fuel Tank Mounting Nut Torque ..............24 N·m (212 in. lb.) Fuel Tank Mounting Screw Torque .............. 24 N·m (212 in. lb.) Fuel Tank Inlet Fitt ing Torque ...............
  • Page 21 Section 1 Safety and General Information Muffl er Exhaust Screw Torque CH270 (M8) ....................24 N·m (212 in. lb.) CH395,CH440 (M10) ................35 N·m (310 in. lb.) Muffl er Shield Screw Torque (M6) ............... 8 N·m (71 in. lb.) Muffl er Shield Screw Torque (M4) CH270 ......................
  • Page 22 Section 1 Safety and General Information Center Compression Ring End Gap New Bore CH270 ....................0.325/0.400 mm (0.013/0.016 in.) CH395 ....................0.650/0.800 mm (0.026/0.032 in.) CH440 ....................0.640/0.800 mm (0.025/0.032 in.) Used Bore (Max.) CH270 ....................1.00 mm (0.039 in.) CH395,CH440 ..................
  • Page 23 Section 1 Safety and General Information Intake Valve Stem O.D. CH270 ....................5.50 mm (0.217 in.) CH395,CH440 ..................6.57 mm (0.259 in.) Max. Wear Limit CH270 ....................5.34 mm (0.210 in.) CH395,CH440 ..................6.40 mm (0.252 in.) Exhaust Valve Stem O.D. CH270 ....................
  • Page 24 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 10% Property Class Noncritical Fasteners Into Aluminum 10.9 12.9 Size 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
  • Page 25 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Grade 2 or 5 Assembled Into Cast Iron or Steel Fasteners Into Aluminum Grade 2 Grade 5 Grade 8...
  • Page 26 Section 1 Safety and General Information 1.22...

  • Page 27: Section 2. Tools & Aids

    SE Tools KLR-82417 To protect seal during camshaft installation. Cylinder Leakdown Tester Kohler 25 761 05-S For checking combustion retention and if cylinder, piston, rings, or valves are worn. Electronic Fuel Injection (EFI) Diagnostic Soft ware Kohler 25 761 23-S Use with Laptop or Desktop PC.
  • Page 28 Tools & Aids Tools (Continued) Description Source/Part No. Hydraulic Valve Lift er Tool Kohler 25 761 38-S To remove and install hydraulic lift ers. Ignition System Tester Kohler 25 455 01-S For testing output on all systems, including CD Off set Wrench (K & M Series) Kohler 52 455 04-S To remove and reinstall cylinder barrel retaining nuts.
  • Page 29 Section 2 Tools & Aids Aids Description Source/Part No. Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S ® Dielectric Grease (Loctite 51360 Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S...
  • Page 30 4. Use a fl at washer with the correct I.D. to slip on the capscrew and approximately 1 in. O.D. (Kohler Part No. 12 468 05-S). Assemble the capscrew and washer to the joint surface of the rod, as shown in Figure 2-1.

  • Page 31: Section 3. Troubleshooting

    Section 3 Troubleshooting Troubleshooting Guide 7. Low compression. 8. Weak spark. When troubles occur, be sure to check the simple 9. Engine overheated-cooling/air circulation causes which, at fi rst, may seem too obvious to be restricted. considered. For example, a starting problem could be 10.
  • Page 32 Section 3 Troubleshooting Engine Overheats External Engine Inspection 1. Air intake/grass screen, cooling fi ns, or cooling Before cleaning or disassembling the engine, make a shrouds clogged. thorough inspection of its external appearance and 2. Excessive engine load. condition. This inspection can give clues to what 3.
  • Page 33 Section 3 Troubleshooting Cleaning the Engine 3. Open the clamp and note the water level in the tube. Aft er inspecting the external condition of the engine, clean the engine thoroughly before disassembling The level in the engine side should be a it.
  • Page 34 Section 3 Troubleshooting If the fl ywheel end is more accessible, use a Compression Test A compression test is best performed on a warm breaker bar and socket on the fl ywheel nut/screw engine. Clean any dirt or debris away from the base of to hold it in position.

  • Page 35: Section 4. Air Cleaner And Air Intake System

    Section 4 Air Cleaner and Air Intake System Air Cleaner Service Check the air cleaner daily or before starting the engine. Check for a buildup of dirt and debris around General the air cleaner system. Keep this area clean. Also check These engines are equipped with one of two air for loose or damaged components.
  • Page 36 Section 4 Air Cleaner and Air Intake System 4. Lightly oil the precleaner with new engine oil. Squeeze the precleaner to evenly distribute the oil and remove any excess. Muffl er 5. Reinstall the precleaner over the paper element. 6. Position the air cleaner cover. Air Intake a.
  • Page 37 2. Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a genuine Kohler element. Handle new elements carefully; do not use if the sealing surfaces are bent or damaged.
  • Page 38 Section 4 Air Cleaner and Air Intake System Remove Foam Element Upper Upper Shroud Shroud Figure 4-8. Remove Foam Element. Blower Blower Lower Lower 3. Wash the foam element in warm water with Housing Housing Shroud Shroud detergent. Rinse the element thoroughly until all traces of detergent are eliminated.

  • Page 39: Section 5. Fuel System And Governor

    Section 5 Fuel System and Governor Section 5 Fuel System and Governor Description Fuel Recommendations This section covers the carbureted fuel systems used on these engines. The governor system is covered at General Recommendations the end of this section. Purchase gasoline in small quantities and store in clean, approved containers.
  • Page 40 Most engines are equipped with an in-line fi lter. replacement hose through a Kohler Service Center. Periodically inspect the fi lter and replace annually or every 300 hours with a genuine Kohler fi lter. See Fuel Filters Figure 5-3. Fuel Tank Filter (If Equipped) A serviceable fuel tank fi...
  • Page 41 Section 5 Fuel System and Governor NOTE: Models with a low-profi le air cleaner do not have the fuel valve. Fuel Valve Every 100 hours of operation clean fuel valve cup Lever of any accumulated debris. If the screen becomes Screen clogged or damaged replace it.
  • Page 42 Section 5 Fuel System and Governor Fuel System Tests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. To fi nd out if the fuel system is causing the problem, perform the following tests. Troubleshooting –...
  • Page 43 1-800-544-2444 to fi nd the names of the nearest Kohler Co. Service Centers or, access NOTE: Certifi ed engines have a limiter cap on the our web site at: www.kohlerengines.com and click on idle fuel adjusting needle.
  • Page 44 Section 5 Fuel System and Governor Adjusting Low Idle Speed 1. Start the engine and run at half thrott le for 5 to 10 minutes to warm up. The engine must be warm before making fi nal sett ings. 2. Low Idle Speed Sett ing: Place the thrott le in the idle or slow position.
  • Page 45 Section 5 Fuel System and Governor 2. Disconnect the breather hose from the valve cover or air cleaner base. Remove the two nuts, the hex fl ange screw securing the base to the head, and air cleaner base from the mounting studs. See Figure 5-9.
  • Page 46 Section 5 Fuel System and Governor 6. Remove disc and wave washer. See Figure 5-16. Main Main Nozzle Nozzle Disc Disc Main Main Figure 5-13. Main Jet Removal. Wave Wave Washer Washer 4. Remove the fuel shut-off fuel bowl, screen, and O-ring.
  • Page 47 Service kit part numbers can be found in our free online parts lookup Kohler PLUS. Go to www.kohlerplus.com and click Figure 5-18. Typical Governor System. Enter as a Guest. When the engine is at rest, and the thrott le control 1.
  • Page 48 Section 5 Fuel System and Governor Initial Adjustment NOTE: Make sure the carburetor is mounted and Make this initial adjustment whenever the governor secured in place when adjustment is being lever is loosened or removed from the cross shaft . To made/checked.

  • Page 49: Section 6. Lubrication System

    Section 6 Lubrication System General NOTE: Using other than service class SJ, or higher oil, or extending oil change intervals longer These engines use a splash lubrication system, than recommended can cause engine supplying necessary lubrication to the crankshaft , damage.
  • Page 50 Section 6 Lubrication System Check Oil Level 3. Checking oil level with a dipstick. Unscrew and The importance of checking and maintaining remove the dipstick; wipe off oil. Reinsert the the proper oil level in the crankcase cannot be dipstick into the oil fi ll tube and rest the dipstick overemphasized.
  • Page 51 Oil Fill Plug Oil Fill Plug operation. Thereaft er, change oil every 100 hours of operation. For an overhauled engine, use Kohler 10W-30 service class, SJ or higher oil for the fi rst 5 hours of operation. Gasket Gasket Change the oil aft er this initial run-in period. Refi ll (fl...
  • Page 52 Section 6 Lubrication System...

  • Page 53: Section 7. Retractable Starter

    Section 7 Retractable Starter Section 7 Retractable Starter WARNING: Spring Under Tension! Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in this section for relieving spring tension. Starter Pawl Repair Handle...
  • Page 54 Section 7 Retractable Starter 2. Pull the starter handle out until the pawls engage the drive cup. Hold the handle in this position and torque the screws to 5.4 N·m (48 in. lb.). Left-Hand Rope Replacement Knot The rope can be replaced without complete starter disassembly.
  • Page 55 4. Carefully inspect the components for wear, cracks, and/or damage. Replace all worn or Figure 7-6. Handle Left-hand Knot. damaged components. Use only genuine Kohler replacement parts. Refer to our free online parts 12. Untie the slip knot and pull on the handle until lookup system www.kohlerplus.com for the...
  • Page 56 Section 7 Retractable Starter Drive Plate Drive Plate Friction Friction Spring Spring Figure 7-8. Center Screw and Drive Plate. 7. Rehook the slack in the rope into the notch of the pulley and rotate the pulley counterclockwise (viewed from pawl side) to re-tension the spring (approximately 4 full turns).

  • Page 57: Section 8. Electrical System And Components

    Section 8 Electrical System and Components This section covers the operation, service, and repair 2. Remove the plug and check its condition. See of the electrical system components. Systems and Inspection following this procedure. Replace the components covered in this section are: plug if necessary.
  • Page 58 Section 8 Electrical System and Components Inspection Inspect the spark plug when it is removed from the cylinder head. The deposits on the tip are an indication of the general condition of the piston rings, valves, and carburetor. Normal and fouled plugs are shown in the following photos: Worn: On a worn plug, the center electrode will be rounded and the gap will be greater than the specifi...
  • Page 59 Section 8 Electrical System and Components Electronic Ignition System These engines are equipped with a dependable magneto breakerless ignition. In such a system, electrical energy is generated by the cutt ing of magnetic fl ux lines generated from the ignition magnet on the engine fl ywheel via the prescribed air gap as it passes the ignition module.
  • Page 60 Install a new spark plug and try to start Kohler Part No. 25 455 01-S. Att ach tester engine. If it still will not start, check other spring clip to a good ground, not to the possible causes (fuel, compression, etc.).
  • Page 61 Section 8 Electrical System and Components Problem Test Conclusion 6. Set an ohmmeter to the Rx1K or Rx10K scale 6. Resistance of the ignition module should and zero. Connect one ohmmeter lead to the be 13.5-18.0 K ohms. kill lead (black/white) terminal and connect the other lead into the spark plug cap.
  • Page 62 Section 8 Electrical System and Components Battery Charging Systems General These engines may be equipped with a 3 amp, 4 amp, 10 amp or 18 amp regulated batt ery charging system. Refer to the appropriate wiring diagram for troubleshooting and servicing your system. Ignition Spark Module...

  • Page 63: Section 9. Disassembly

    Section 8 Electrical System and Components Ignition Module Rectifi er- Regulator Spark Stator Plug Battery Fuse 12 Volt Battery Switch Oil Control Relay Module Starter Motor Oil Float Switch Figure 8-7. Wiring Diagram-10/18 Amp Charging System, With Rectifi er-Regulator. NOTE: Observe the following guidelines to Rectifi...
  • Page 64 Section 8 Electrical System and Components B+ Charge (White) Ground (Black) B+ Charge (White) Ground (Black) Stator Leads Stator Leads Figure 8-9. 10 Amp Rectifi er-Regulator. Figure 8-8. 18 Amp Rectifi er-Regulator. Rectifi ed Only (Non-Regulated) Systems Some engines are equipped with a rectifi ed only, non-regulated charging system, with output ranging from 3 amps to 4 amps.
  • Page 65 Section 8 Electrical System and Components Problem Test Conclusion 1. Refer to Figure 8-10. Separate the 1. If voltage is 14.0-15.0 volts and charge rate bullet connector in the white lead increases when load is applied, the charging from the rectifi er-regulator. Connect system is OK and the batt ery was fully an ammeter from the female terminal charged.
  • Page 66 Section 8 Electrical System and Components Battery General A 12 volt batt ery (not furnished) with a minimum current rating of 230 cold cranking amps/18 amp hours should be suffi cient for cranking most electric start engine models. The actual cold cranking requirement depends on engine size, application and starting temperatures.
  • Page 67 Section 8 Electrical System and Components Troubleshooting Guide - Electric Starting System Problem Test Conclusion 1. Test batt ery on unit. 1. a. Batt ery voltage should be at least 12 volts. If low charge batt ery. a. Connect a DC voltmeter across the batt ery terminals and read batt ery voltage (key b.
  • Page 68 Figure 8-13. Disassembled Drive Components. Screws 5. Inspect the gears for damage or wear. 6. Clean the gears as required. 7. Apply a small amount of Kohler electric starter drive lubricant, (see Section 2) to the geartrain. See Figure 8-14. Drive End Cap Screw Figure 8-11.
  • Page 69 Section 8 Electrical System and Components 8. Reinstall the dust cover and insert the drive pinion into the geartrain. See Figure 8-15. Dust Cover Drive Pinion Figure 8-15. Reinstall Dust Cover and Drive Pinion. 9. Assemble the drive end cap onto the drive pinion.
  • Page 70 Section 8 Electrical System and Components 8.14...
  • Page 71 Section 9 Disassembly Section 9 Disassembly General 24. Remove crankcase and closure plate seals and bearings. Clean all parts thoroughly as the engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There Disconnect Spark Plug Lead are many commercially available cleaners that will 1.
  • Page 72 Section 9 Disassembly NOTE: Models with the low-profi le air cleaner do not have the fuel shut-off valve. Instead, turn off the fuel at the fuel supply. Drain Oil From Crankcase 1. Remove one of the oil drain plugs and one of the oil fi...
  • Page 73 Section 9 Disassembly Remove the Low-Profi le Air Cleaner Base Remove the air cleaner base from the engine as follows: Hex Nuts Hex Nuts 1. Remove one hex fl ange screw and two hex fl ange nuts securing the air cleaner base to the carburetor.
  • Page 74 Section 9 Disassembly Remove Fuel Tank (If Equipped) Remove External Throttle, Governor and NOTE: If no fuel tank is equipped, loosen the clamp Choke Linkage and disconnect the fuel line from the inlet 1. Mark which hole location the governor spring is the carburetor.
  • Page 75 Section 9 Disassembly Remove Carburetor WARNING Gasoline is extremely fl ammable and its vapors can explode if ignited. Screws Screws Gasoline may be present in the carburetor and fuel system. Gasoline is extremely fl ammable, and its vapors can explode if ignited. Keep sparks, open fl ames and other sources of ignition away from the engine.
  • Page 76 Section 9 Disassembly 4. Remove the hex fl ange screws securing the lower shield and remove the shield. See Figures 9-23 and 9-24. Screw Screw Hex Screws Hex Screws Figure 9-20. Remove CH395, CH440 Blower Housing Hex Flange Screw Under Cylinder Head. 2.
  • Page 77 Section 9 Disassembly Starter Starter ™ ™ Oil Sentry Oil Sentry Ground Ground Wires Wires Wire Wire Wires Wires Module Module Bullet Bullet Connectors Connectors Rectifi er- Rectifi er- Ignition Ignition Regulator Regulator Module Module Wire Wire Wire Wire Figure 9-27. Disconnect Wires from Control Panel. 2.
  • Page 78 Section 9 Disassembly Remove Valve Cover/Breather, Rocker Arms, Push Rods and Cylinder Head Assembly 1. Remove the hex fl ange screw and washer and remove the valve cover and gasket from the Screws Screws engine. See Figure 9-30. The breather assembly is inside the valve cover.
  • Page 79 Section 9 Disassembly Hex Screws Hex Screws Figure 9-34. Valve Keeper Removal. Figure 9-36. Remove Ignition Module Screws. 2. Remove and replace the valve stem seals whenever the cylinder head is serviced or Remove Flywheel disassembled. See Figure 9-35. NOTE: Whenever possible, an impact wrench should be used to loosen the fl...
  • Page 80 Section 9 Disassembly 3. Remove hex screw and shield (CH270 only) on right side of fl ywheel (required for use of puller in next step). See Figure 9-41. Screw Screw Shield Shield Figure 9-38. Removing Flywheel Nut Using Strap Wrench. Figure 9-41.
  • Page 81 Section 9 Disassembly 2. Remove the closure plate gasket and dowel pins if required from the crankcase. See Figures 9-46 and 9-47. NOTE: Do not pry on the gasket surface of the crankcase or closure plate, as this can cause damage and leakage. Dowel Pins Dowel Pins Stator Wire...
  • Page 82 Section 9 Disassembly Screws Screws Connecting Connecting Rod End Cap Rod End Cap Figure 9-48. Balance Shaft Removal. Figure 9-50. Removing Piston and Connecting Rod. Remove Camshaft and Valve Tappets 1. Remove the camshaft by pulling it straight out of 2.
  • Page 83 Section 9 Disassembly 2. Pull the grommet assembly from the crankcase on the inside. 3. Remove the two hex screws securing the Oil Sentry™ fl oat switch to the crankcase. Remove the fl oat switch assembly. See Figure 9-53. Governor Governor Shaft Shaft...
  • Page 84 Section 9 Disassembly NOTE: Do not pry on the gasket surface of the closure plate, as this can cause damage and leakage. Figure 9-58. Removing Governor Assembly Cup and Washer. NOTE: Take note of the orientation of the governor gear components. See Figure 9-59. Figure 9-61.
  • Page 85 Section 9 Disassembly 3. Remove the oil seal from the closure plate. See Figure 9-66. Figure 9-63. Removing Governor Cross Shaft Hitch Pin. 4. Remove the cross shaft from inside the crankcase. Figure 9-66. Closure Plate Seal Removal. Remove Crankcase and Closure Plate 4.
  • Page 86 Section 9 Disassembly 9.16...

  • Page 87: Section 10. Inspection And Reconditioning

    Section 10 Inspection and Reconditioning Section 10 Inspection and Reconditioning This section covers the operation, inspection, and Automatic Compression Release (ACR) repair/reconditioning of major internal engine These engines are equipped with an Automatic components. The following components are not Compression Release (ACR) mechanism. ACR lowers covered in this section.
  • Page 88 Section 10 Inspection and Reconditioning Benefi ts As a result of the reduced compression at cranking Inspect speeds, several important benefi ts are obtained: Tappets 1. Manual (retractable) starting is much easier. Without ACR, manual starting would be virtually impossible. 2.
  • Page 89 Section 10 Inspection and Reconditioning CH440 Cam Lobe Dimension A Valve Dimension A Service Limit 32.266 mm 32.642 mm INTAKE (1.3097 in.) (1.2851 in.) 32.260 mm 31.610 mm EXHAUST (1.2701 in.) (1.2445 in.) Figure 10-5. Camshaft Journal Checking. Camshaft Journal Specifi cations Engine Model Dimension Limit...
  • Page 90 Check the size frequently. inside micrometer to determine the amount of wear (refer to Section 1, Specifi cations and Tolerances). See NOTE: Kohler pistons are custom-machined to Figure 10-6. exacting tolerances. When over-sizing a cylinder, it should be machined exactly 0.25 mm (0.010 in.) over the new diameter...
  • Page 91 Section 10 Inspection and Reconditioning Measuring Piston-to-Bore Clearance Before installing the piston into the cylinder bore, it is necessary that the clearance be accurately checked. This step is oft en overlooked, and if the clearances are not within specifi cations, engine failure will usually result.
  • Page 92 Section 10 Inspection and Reconditioning Cylinder Head and Valves Figure 10-9. Valve and Seat Measuring Locations. CH270 Valve Specifi cations Item Dimension Intake Exhaust Head Diameter 26.875-27.125 mm 24.875-25.125 mm (1.0581-1.0679 in.) (0.9793-0.9892 in.) Valve Length 63.3-63.9 mm (2.4921-2.5157) 63.3-63.9 mm (2.4921-2.5157) Stem Diameter 5.5 mm (0.217 in.) 5.438 mm (0.214 in.)
  • Page 93 Section 10 Inspection and Reconditioning Inspection and Service Aft er cleaning, check the fl atness of the cylinder head and the corresponding top surface of the crankcase, using a surface plate or piece of glass and feeler gauge. The maximum allowable out of fl atness is 0.1 mm (0.0039 in.).
  • Page 94 Section 10 Inspection and Reconditioning Overheating: An exhaust valve subject to overheating will have a dark discoloration in the area above the valve guide. Worn guides and faulty valve springs Excessive Combustion Temperatures: The white may cause this condition. Also check for clogged air deposits seen here indicate very high combustion intake, and blocked fi...
  • Page 95 Section 10 Inspection and Reconditioning Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press-fi tt ed into the cylinder head. The inserts are not replaceable but can be reconditioned if not too badly pitt ed or distorted. If cracked or badly warped, the cylinder head should be replaced.
  • Page 96 Section 10 Inspection and Reconditioning Scratches on rings and pistons are caused by abrasive material such as carbon, dirt, or pieces of hard metal. Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly aft er ignition.
  • Page 97 Section 10 Inspection and Reconditioning Replacement pistons are available in STD bore size, 5. Aft er installing the new compression (top and and 0.25 mm (0.010 in.) oversize. Replacement pistons middle) rings on the piston, check the piston- include new piston ring sets and new piston pins. to-ring side clearance.
  • Page 98 Section 10 Inspection and Reconditioning Service replacement connecting rods are available in STD size and 0.25 mm (0.010 in.) undersize. Piston Ring The 0.25 mm (0.010 in.) undersized rods have an identifi cation marking on the lower end of the rod shank.

  • Page 99: Section 11. Reassembly

    Section 11 Reassembly Section 11 Reassembly General 29. Testing the engine. NOTE: Make sure the engine is assembled using Install Crankcase Bearings and Oil Seals all specifi ed torque values, tightening sequences, and clearances. Failure to observe 1. Make sure there are no nicks, burrs, or damage specifi...
  • Page 100 Section 11 Reassembly NOTE: In steps 3 and 4 that follow, position Install to a depth of: the oil seals with the manufacturer’s CH270, CH440 0.0-1.0 mm (0.0-0.039 in.) from the identifi cation marks visible and facing outer surface you. CH395 2.0 mm (0.079 in.) from the outer surface Using an appropriate seal driver, install the oil seal into the closure plate to the depth specifi...
  • Page 101 Section 11 Reassembly Governor Gear Assembly Gasket Surface Governor Governor Hitch Pin Hitch Pin Cross Shaft Cross Shaft Index Flat Index Flat Thrust Thrust Cup & Washer Washer Washer Figure 11-7. Installing Governor Gear Assembly. Figure 11-9. Installing Thrust Washer and Hitch 3.
  • Page 102 Section 11 Reassembly NOTE: The governor gear shaft is pressed into the Height Governor closure plate and should not be removed. Gear Shaft 3. Install one thrust washer onto the governor cross Closure Plate shaft and slide the shaft up through the inside of Sealing Surface the crankcase.
  • Page 103 Section 11 Reassembly Grommet Grommet Assembly Assembly Oil Sentry Oil Sentry Float Switch Float Switch Figure 11-18. Oil Sentry™ Float Switch Mounting. Figure 11-16. Installing Governor Shaft. 2. Route the wire lead grommet assembly through the crankshaft housing. See Figure 11-18. 8.
  • Page 104 Section 11 Reassembly Match Marks Match Marks Oil Hole Oil Hole Location Location Connecting Connecting Rod Offset Rod Offset Figure 11-22. Connecting Rod Details. Figure 11-20. Installing Crankshaft. 2. Stagger the piston rings in the grooves as shown Install Connecting Rod with Piston and in Figure 11-23.
  • Page 105 Section 11 Reassembly 7. Torque both screws in increments to: CH270 12 N·m (106 in. lb.) CH395, CH440 20 N·m (177 in. lb.) Install Balance Shaft (If Equipped) 1. Position the crankshaft so the timing mark on the larger crankgear is in the 8 o'clock position. 2.
  • Page 106 Section 11 Reassembly 3. Rotate the crankshaft to TDC so the timing mark (dimple) on the smaller crankgear is in the 4 Dowel Pins Dowel Pins o’clock position. Install the camshaft into the crankcase, aligning the timing marks on the two gears.
  • Page 107 Section 11 Reassembly Torque Torque Screw Screw Bracket Bracket Figure 11-34. Install Bracket and Torque Screw. Figure 11-32. CH395, CH440 Closure Plate Torque Sequence. Install Flywheel Install Stator (If Equipped) WARNING: Damaging Crankshaft and 1. Position the stator aligning the mounting holes so Flywheel Can Cause Personal Injury! the leads are in the 3 o'clock position.
  • Page 108 Section 11 Reassembly 1. Install the woodruff key into the keyway of the crankshaft . Make sure that the key is properly seated and parallel with taper of shaft . See Figure 11-36. Flywheel Flywheel Woodruff Key Woodruff Key Figure 11-38. Install Flywheel Fan. 5.
  • Page 109 Section 11 Reassembly Magnet Magnet Feeler Feeler Gauge Gauge Figure 11-40. Torque Flywheel Nut. Figure 11-42. Setting Ignition Module Air Gap. Install Ignition Module 4. Insert a 0.254 mm (0.010 in.) fl at feeler gauge between the leg of the module and the magnet. 1.
  • Page 110 Section 11 Reassembly Route Wire Here Route Wire Here Module Terminal Module Terminal Figure 11-45. Installing Valve Retainers. Install Cylinder Head 1. Check to make sure there are no nicks or burrs Figure 11-43. Connect Kill Wire To Module. on the sealing surfaces of the cylinder head or crankcase.
  • Page 111 Section 11 Reassembly Figure 11-47. Cylinder Head Screws Torquing Locknuts Locknuts Sequence. Figure 11-49. Installing Rocker Arms, Adjusters Install Push Rods and Rocker Arms and Locknuts. NOTE: Push rods should always be installed in the original location. 4. Adjust the valve tappet clearance as follows: 1.
  • Page 112 Section 11 Reassembly d. Hold the adjuster from turning and tighten the locknut. Torque locknut to 10 N·m (89 in. lb.). See Figure 11-51. Valve Cover Valve Cover Screw Screw Figure 11-53. Torquing Valve Cover Screw. Install Fuel Tank Supports and Shut Down Figure 11-51.
  • Page 113 Section 11 Reassembly 2. Push the carburetor all the way onto the studs. Fuel Tank See Figure 11-58. Bracket Install Hex Install Hex Flange Flange Screws Screws Figure 11-55. Install Fuel Tank Bracket. Install Hex Flange Fuel Tank Bracket Screws Figure 11-58.
  • Page 114 Section 11 Reassembly Hex Screw Hex Screw Position Shield Position Shield Breather Breather on Stud on Stud Hose Hose Hex Nuts Hex Nuts Figure 11-60. Position Upper Shield. Figure 11-62. Air Cleaner Base Installation. 2. Install one hex fl ange screw in the rear of top air 4.
  • Page 115 Section 11 Reassembly Hex Screw Hex Screw Breather Breather Hose Hose Hex Screws Hex Screws Hex Nuts Hex Nuts Figure 11-64. Install Upper Heat Shield. Figure 11-66. Air Cleaner Base Installation. 2. Install lower shield on the cylinder and secure Install Electric Starter and Control Panel with two hex fl...
  • Page 116 Section 11 Reassembly 3. Mount the control panel to the crankcase and Hex Nuts Hex Nuts secure with two hex fl ange screws. Ensure the ground wires are placed between the screw and the bracket. Torque the screws to 24 N·m (212 in. lb.). See Figure 11-69. Hex Screws Hex Screws Figure 11-71.
  • Page 117 Section 11 Reassembly 2. Pull the rope handle to engage the pawls and CH395, CH440 center the starter to the drive cup. Hold in this 3. Push the governor lever in the direction indicated position and torque the mounting screws to in Figure 11-76 and hold in this position.
  • Page 118 Section 11 Reassembly Throttle Throttle Lever Lever Spring Spring Washer Tab Washer Tab In Slot In Slot Figure 11-78. Install Throttle Lever for CH395, Figure 11-79. Throttle Lever Hardware. CH440. 5. Install a nylon washer, wave spring, and tabbed washer (with tab engaged in slot) on the stud above the thrott le lever and secure with a hex fl...
  • Page 119 Section 11 Reassembly Throttle Control Pivot Lever Governor Lever Throttle Control Lever CH395 Engines 7-12% Droop 3-8% Droop Engine Speed Hole Hole Spring Color Spring Color Combination Combination 3801-4000 Yellow #2-B 3601-3800 Yellow #2-B Purple #1-A 3401-3600 Yellow #2-B 3201-3400 Yellow #1-B 3001-3200...
  • Page 120 Section 11 Reassembly Install Oil Sentry Module ™ NOTE: If the Oil Sentry™ module is mounted inside Hex Nuts Hex Nuts the control panel, skip this step. 1. Install the Oil Sentry™ module and secure with one hex screw. See Figure 11-80. Torque the screw to 3.5 N·m (31 in.
  • Page 121 Section 11 Reassembly Fuel Line Fuel Line Clip Clip Fuel Line Fuel Line Clamp Clamp Screws Screws Figure 11-84. Connecting Fuel Line. Figure 11-86. Install CH270 Muffl er/Heat Shield Assembly. Install Carburetor Cover (If Equipped) 1. Install the outer air cleaner cover onto the studs, over the carburetor.
  • Page 122 Section 11 Reassembly Install Air Cleaner Element and Cover Install the Quad-Clean Air Cleaner ™ 1. Place the air cleaner element with precleaner onto the boss on the air cleaner base. See Figure 11-89. Element Element Element Element Cleaner Cleaner Base Base Figure 11-91.
  • Page 123 Section 11 Reassembly Low Idle Speed Low Idle Speed Adjustment Screw Adjustment Screw Figure 11-92. Low Idle Speed Adjustment Screw. 2. The maximum no load high–idle engine speed is 3750 RPM. Adjust the high speed stop screw as necessary. See Figure 11-93. High Speed High Speed Stop Screw...
  • Page 124 Section 11 Reassembly 11.26...
  • Page 126 FORM NO.: 17 690 01 Rev. D ISSUED: 5/10 REVISED: 1/11 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 © 2011 by Kohler Co. All rights reserved.

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Command pro ch395Command pro ch440

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