Kohler Command PRO CH440 Manuals

Manuals and User Guides for Kohler Command PRO CH440. We have 8 Kohler Command PRO CH440 manuals available for free PDF download: Owner's Manual, Service Manual

Kohler Command PRO CH440 Service Manual (127 pages)

HORIZONTAL CRANKSHAFT

Brand: Kohler | Category: Crankshaft | Size: 6 MB

Table of Contents
3
Safety Precautions
5
Section 1. Safety and General Information
5
Section 2. Tools & Aids
27
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
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
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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California Proposition 65 Warning
2
Congratulations
2
Table of Contents
3
Safety Precautions
4
Symbols Associated with this Product
5
Control and Service Point Locations
6
Oil Recommendations
7
- Oil Type
  7
Fuel Recommendations
7
- General Fuel Recommendations
  7
- Fuel Type
  7
Operating Instructions
8
- Pre-Start Checklist
  8
- Cold Weather Starting Hints
  8
- Starting
  8
- Stopping
  9
Operating
10
- Angle of Operation
  10
- Cooling
  10
Maintenance Instructions
11
- Maintenance Schedule
  11
Check Oil Level
11
- Change Oil
  12
Service Precleaner and Air Cleaner Element
13
- Service Precleaner (if Equipped)
  13
- Service Paper Element
  14
Ignition System
15
Check Spark Plug
15
Fuel Tank Filter
15
Fuel Valve
16
Clean Air Intake/Cooling Areas
17
Carburetor Troubleshooting and Adjustments
18
Troubleshooting
18
Troubleshooting
19
Storage
19
Transport
19
Major Repair
20
Parts Ordering
20
Engine Warranty
21
Emission Control System Warranty
22

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