KOHLER ECH440 Command Pro EFI Engine Owner’s Manual

KOHLER ECH440 Command Pro EFI Engine

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. Warranty coverage as outlined in the warranty card and on KohlerEngines. com. Please review carefully as it provides your specifi c rights and obligations.
To maintain compliance with applicable emission regulations, exhaust system backpressure may not exceed limits which can be found on KohlerEngines. com. Search by Model No., then select Specs tab. Kohler Engines has published CO2 values on the KohlerEngines.com website. Record engine information to reference when ordering parts or obtaining warranty coverage.

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 fi res and severe burns. Do not fi ll 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 the ignition. Never use gasoline as a cleaning agent.
• 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.
• 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.
• 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.
• 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.
• High-Pressure Fluids can puncture skin and cause severe injury or death. Do not work on fuel system without proper training or safety equipment. Fluid puncture injuries are highly toxic and hazardous. If an injury occurs, seek immediate medical attention.
• This product can expose you to chemicals including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov.

CAUTION
Electrical Shock can cause injury. Do not touch wires while engine is running.

Symbols

Overview

• A Air Cleaner Cover
• B Bail
• C Precleaner
• D Paper Element
• E Air Cleaner Base
• F Quad-Clean™ Air Cleaner
• G Starter Handle
• H Retractable Starter
• I Oil Drain Plug
• J Dipstick/Oil Fill Plug
• K Throttle Lever
• L Fuel Tank
• M Fuel Cap
• N Low-Profi le Air Cleaner
• O Screw
• P Foam Element
• Q Oil Fill Plug
• R Dipstick
• S Tube

Pre-Start Checklist

1. Check oil level. Add oil if low. Do not overfi ll.
2. Check fuel level. Add fuel if low. Check fuel system components and lines for leaks.
3. Check and clean cooling areas, air intake areas and external surfaces of engine (particularly after storage).
4. Check that air cleaner component and all shrouds, equipment covers, and guards are in place and securely fastened.
5. Check spark arrestor (if equipped).

Starting

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.
• 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.

NOTE:

• To prime, a dry fuel system, turn key switch to ON position for one minute. Allow fuel pump to cycle and prime system. Turn key switch OFF.
• Extend the starter cord periodically to check its condition. If cord is frayed have it replaced immediately by a Kohler authorized dealer.
• Do not crank the engine continuously for more than 10 seconds. Allow a 60-second cool-down period between starting attempts. Failure to follow these guidelines can burn out starter motor.

If the engine develops sufficient speed to disengage the starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart the engine. If the starter is engaged while the flywheel is rotating, the starter pinion and flywheel ring gear may clash, resulting in damage to the starter.

1. Turn fuel shut-off valve to ON position (if equipped).

2. Turn engine on/off switch to ON position (if equipped).

3. Start engine as follows:
   Place throttle control midway between SLOW and FAST positions.

4. Retractable Start: Slowly pull starter handle until just past compression-STOP! Return starter handle; fi rmly pull straight out to avoid excessive rope wear from starter rope guide. Electric Start: Activate starter switch. Release switch as soon as engine starts. If starter does not turn engine over, shut off starter immediately. Do not make further attempts to start engine until condition is corrected. Do not jump start. See your Kohler authorized dealer for trouble analysis.

Cold Weather Starting Hints

1. Use proper oil for the temperature expected.
2. Disengage all possible external loads.
3. Use fresh winter-grade fuel. Winter grade fuel has higher volatility to improve starting.

Stopping

1. If possible, remove load by disengaging all PTO-driven attachments.
2. If equipped, move throttle control to slow or idle position; stop engine.
3. If equipped, close fuel shut-off valve.

Angle of Operation
Refer to operating instructions of equipment this engine powers. Do not operate this engine exceeding the maximum angle of operation; see specifi cation table. Engine damage could result from insuffi cient lubrication.

Engine Speed
NOTE: Do not tamper with the governor setting to increase maximum engine speed. Overspeed is hazardous and will void the warranty.

Throttle Body Icing

NOTE:
Running the engine with a cover positioned for cold weather operation in normal conditions can damage the engine. Throttle body icing can take place when certain combinations of temperature and humidity exist. The result of throttle body icing is rough running at idle or low speed as well as black or white smoke. To reduce the likelihood of throttle body icing, air cleaner cover can be rotated to draw warmer air from the muffler side. For cold weather operation, position air cleaner cover with snowfl ake decal out.
For normal operation, position air cleaner cover with sun decal out.

Maintenance Instructions

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.

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 found at KohlerEngines.com or 1-800-544-2444 (U.S. and Canada).

Maintenance Schedule

• Change oil (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Every 50 Hours or Annually

• Service/replace Quad-Clean™ precleaner. Every 100 Hours or Annually¹

• Clean low-profi le air cleaner element.

• Change oil.

• Clean cooling areas. Every 200 Hours

• Replace Quad-Clean™ air cleaner element. Every 300 Hours

• Replace low-profi le air cleaner element.

• Check fuel filters (tank outlet filter and in-line filter) and clean or replace if needed (if equipped). Every 300 Hours¹

• Replace unique Electronic Fuel Injection (EFI) fuel filter. Every 300 Hours²

• Check and adjust valve clearance when the engine is cold.
  Every 300 Hours³ (Not available for the ECH440LE engine model)

• Change oil (KOHLER PRO 10W-50 oil only). Every 500 Hours or Annually¹

• Replace the spark plug and set gap.

1. Perform these procedures more frequently under severe, dusty, dirty conditions.
2. Have a Kohler authorized dealer perform this service.
3. The option only if using KOHLER® PRO oil.

Oil Recommendations

ECH440
All-season KOHLER® PRO 10W-50 Synthetic Oil is the ideal oil for KOHLER engines. It is specifi cally formulated to extend the oil change interval to 300 Hours. Contact your Kohler authorized dealer for availability. 300-Hour oil change intervals are exclusive to and only authorized on KOHLER engines that utilize the KOHLER PRO 10W-50 Synthetic Oil. Alternative engine oils may be used with KOHLER engines but require 100-Hour oil change intervals for proper maintenance. Oil must be API (American Petroleum Institute) service class SJ or higher. Select viscosity based on air temperature at time of operation as shown below.

ECH440LE
Use ILSAC (International Lubricants Standardization and Approval Committee) GF-5 motor oils for best performance. Select viscosity based on air temperature at time of operation as shown in table below.

Check Oil Level

NOTE:
To prevent extensive engine wear or damage, never run engine with oil level below or above the operating range indicator on dipstick.

Ensure the engine is cool and level. Clean oil fi ll/dipstick areas of any debris.

1. Check oil level using dipstick or oil fi ll plug.
   • Threaded cap dipstick: Remove dipstick; wipe oil off . Reinsert the dipstick into tube; rest on oil fi ll neck; turn counterclockwise until cap drops down to lowest point of thread leads; do not thread cap onto the tube. Remove dipstick; check the oil level. The level should be at top of the indicator on the dipstick.
   • Push-on cap dipstick: Remove dipstick; wipe oil off. Reinsert the dipstick into tube; press down completely. Remove dipstick; check oil level. Level should be at top of the indicator on the dipstick.
   • Remove oil fi ll plug. Level should be up to point of overfl owing fi ller neck.
2. If oil is low, add oil up to top of indicator mark on dipstick or to point of overfl owing fi ller neck.
3. Reinstall and secure dipstick or oil fill plug.

Change Oil
Change oil while the engine is warm.

1. Clean area around oil fi ll cap/dipstick and drain plug.
2. Remove the drain plug and oil fi ll cap/dipstick. Drain oil completely.
3. Reinstall the drain plug. Torque to 13 ft. lb. (17.6 N·m).
4. Fill crankcase with new oil, up to the top of indicator mark on dipstick or to point of overfl owing fi ller neck.
5. Reinstall and secure oil fi ll cap/dipstick.
6. Dispose of used oil in accordance with local ordinances.

Oil Sentry™ (if equipped)
This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry™ may not shut down a running engine before damage occurs. In some applications this switch may activate a warning signal. Read your equipment manuals for more information.

Fuel Recommendations

WARNING
Explosive Fuel can cause fi res and severe burns. Do not fi ll 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 the ignition. Never use gasoline as a cleaning agent.

NOTE:
E15, E20 and E85 are NOT approved and should NOT be used; eff ects 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 overfi ll fuel tank.
• Do not use gasoline older than 30 days.

Add Fuel

WARNING

• Explosive Fuel can cause fires and severe burns. Do not fi ll 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 fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from the ignition. Never use gasoline as a cleaning agent.

Ensure engine is cool.

1. Clean area around fuel cap.
2. Remove fuel cap. Fill to base of filler neck. Do not overfi ll fuel tank. Leave room for fuel to expand.
3. Reinstall the fuel cap and tighten it securely.

Fuel Line
High pressure fuel line meeting SAE R12 standard must be installed on Kohler Co. engines equipped with an EFI system.

Spark Plugs

CAUTION
Electrical Shock can cause injury. Do not touch wires while engine is running.

Clean out spark plug recess. Remove plug and replace.

1. Check gap using wire feeler gauge. Adjust gap, see specifi cation table for adjustment.
2. Install plug into cylinder head.
3. Torque plug to 20 ft. lb. (27 N·m).

Jump Starting
Follow all safety guidelines and procedures provided by battery manufacturer and/or original equipment manufacturer (OEM). Failure to follow proper procedures may result in serious personal injury and/or non-warrantable damage to engine’s EFI components.

Electronic Fuel Injection (EFI) System
EFI is an electronically-controlled fuel management system which is monitored by an Electronic Control Unit (ECU). If equipped with a Malfunction Indicator Light (MIL), this light will illuminate if problems or faults are detected. Servicing by a Kohler authorized dealer is necessary.

Fuel System Components
High-pressure components inside fuel pump module are not serviceable. Engines are equipped with a special EFI fuel fi lter. See Maintenance Schedule.

Fuse Replacement
This engine has two (2) blade-type automotive fuses. Replacement fuses must have same rating as a blown fuse. Use fuse chart below to determine the correct fuse.

Air Cleaner

NOTE:

• Running the engine with a cover positioned for cold weather operation in normal conditions can damage engine.
• Operating an engine with loose or damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.
• The paper elements cannot be blown out with compressed air.

Quad-Clean™
Move bails on air cleaner cover down; remove latches from under tabs on base; remove cover.

Precleaner:

1. Remove precleaner from the paper element.
2. Replace or wash cleaner in warm water with detergent. Rinse and allow to air dry.
3. Lightly oil precleaner with new engine oil; squeeze out excess oil.
4. Reinstall pre-cleaner over paper element.

Paper Element:

1. Separate cleaner from element; service precleaner and replace paper element.
2. Install new paper element on base; install precleaner over paper element.

Position air cleaner cover for normal operation (sun decal out) or cold weather operation
(snowfl ake decal out); place latches under tabs on base; lift up bails to secure cover.

Low-Profile

1. Remove screw and air cleaner cover.
2. Remove foam element from base.
3. Wash foam elements in warm water with detergent. Rinse and allow to air dry.
4. Lightly oil foam element with new engine oil; squeeze out excess oil.
5. Reinstall foam element into base.
6. Reinstall cover and secure with screw.

Breather Tube
Ensure both ends of breather tube are properly connected.

Air Cooling

WARNING

• Hot Parts can cause severe burns.
• Do not touch the engine while operating or just after stopping.
• Never operate the engine with heat shields or guards removed.
• Proper cooling is essential. To prevent overheating, clean screens, cooling fi ns, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. See Maintenance Schedule.

Repairs/Service Parts
We recommend that you use a Kohler authorized dealer for all maintenance, service, and replacement parts for engine. To fi nd a Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

Storage
If the engine will be out of service for 2 months or more follow the 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 the engine is still warm from operation (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Remove spark plug(s) and pour about 1 oz. of engine oil into the cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil.
3. Disconnect negative (-) battery cable.
4. Store the engine in a clean, dry place.

Troubleshooting

Do not attempt to service or replace major engine components, or any items that require special timing or adjustment procedures. This work should be performed by a Kohler authorized dealer.

Exceeding the maximum angle of operation may cause engine damage from insuffi cient lubrication. Additional specifi cation information can be found in service manual at KohlerEngines.com. Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.

Emission Control System Exhaust Emission Control System for model ECH440 is EM, O2S, ECM, TBI and model ECH440LE is EM, O2S, ECM, TBI, TWC for U.S. EPA, California, and Europe.

NOTE:
Tampering with the engine and its emission control system voids the EPA Certifi cate of Conformity, ARB Executive Order, and EU type approval.

References

• Engines | KOHLER Power
• P65Warnings.ca.gov

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