Kohler ECH440 User manual

117 690 14 Rev. E KohlerEngines.com

ECH440 & ECH440LE

Service Manual

2 Safety

3 Maintenance

5 Speciﬁ cations

28 Tools and Aids

31 Troubleshooting

35 Air Cleaner/Intake

37 Electronic Fuel Injection (EFI) System

65 Governor System

66 Lubrication System

68 Electrical System

74 Starter System

79 Disassembly/Inspection and Service

94 Reassembly

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.

2

Safety

KohlerEngines.com 17 690 14 Rev. E

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 ﬂ ammable

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 ignition. Never use gasoline

as a cleaning agent.

WARNING

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.

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.

WARNING

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.

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.

WARNING

Cleaning Solvents can

cause severe injury or

death.

Use only in well

ventilated areas away

from ignition sources.

Carburetor cleaners and solvents

are extremely ﬂ ammable. Follow

cleaner manufacturer’s warnings

and instructions on its proper and

safe use. Never use gasoline as a

cleaning agent.

CAUTION

Electrical Shock can

cause injury.

Do not touch wires while

engine is running.

CAUTION

Damaging Crankshaft

and Flywheel can cause

personal injury.

Using improper procedures can

lead to broken fragments. Broken

fragments could be thrown from

engine. Always observe and use

precautions and procedures when

installing ﬂ ywheel.

CAUTION

Failure to utilize or

reassemble debris

screen as designed could

result in debris screen

failure and serious

personal injury.

WARNING

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.

WARNING

Explosive Fuel can

cause ﬁ res and severe

burns.

Fuel system ALWAYS

remains under HIGH

PRESSURE.

Wrap a shop towel completely

around fuel pump module

connector. Press release button(s)

and slowly pull connector away

from fuel pump module allowing

shop towel to absorb any residual

fuel in high pressure fuel line. Any

spilled fuel must be completely

wiped up immediately.

WARNING

Uncoiling Spring can

cause severe injury.

Wear safety goggles or

face protection when

servicing retractable

starter.

Retractable starters contain a

powerful, recoil spring that is

under tension. Always wear safety

goggles when servicing retractable

starters and carefully follow

instructions in Retractable Starter

for relieving spring tension.

3

Maintenance

17 690 14 Rev. E KohlerEngines.com

MAINTENANCE INSTRUCTIONS

WARNING

Before working on engine or equipment, disable engine as

follows: 1) Disconnect spark plug lead(s). 2) Disconnect

negative (–) battery cable from battery.

Accidental Starts can cause severe injury or

death.

Disconnect and ground spark plug lead(s)

before servicing.

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.

MAINTENANCE SCHEDULE

After ﬁ rst 5 Hours

● Change oil (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Lubrication System

Every 50 Hours or Annually

● Service/replace Quad-Clean™ precleaner. Air Cleaner/Intake

Every 100 Hours or Annually¹

● Clean low-proﬁ le air cleaner element. Air Cleaner/Intake

● Change oil. Lubrication System

● Clean cooling areas. Air Cleaner/Intake

Every 200 Hours

● Replace Quad-Clean™ air cleaner element. Air Cleaner/Intake

Every 300 Hours

● Replace low-proﬁ le air cleaner element. Air Cleaner/Intake

● Check fuel ﬁ lters (tank outlet ﬁ lter and in-line ﬁ lter) clean or replace if needed (if

equipped). Fuel System

Every 300 Hours¹

● Replace unique Electronic Fuel Injection (EFI) fuel ﬁ lter.

Every 300 Hours²

● Check and adjust valve clearance when engine is cold. Reassembly

Every 300 Hours³ (Not available for ECH440LE engine model)

● Change oil (KOHLER PRO 10W-50 oil only). Lubrication System

Every 500 Hours or Annually¹

● Replace spark plug and set gap. Electrical System

¹ Perform these procedures more frequently under severe, dusty, dirty conditions.

² Have a Kohler authorized dealer perform this service.

³ Option only if using KOHLER® PRO oil.

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁ nd a local Kohler authorized

dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

4

Maintenance

KohlerEngines.com 17 690 14 Rev. E

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.

Alternative oils (including synthetic) may be used, but

then oil change interval must be 100 hours. Extending oil

change intervals beyond 100 hours with non-Kohler PRO

10W-50 oil will void warranty. Oil must be API (American

Petroleum Institute) service class SJ or higher. Select

viscosity based on air temperature at time of operation

as shown in table below.

°F -20 020324060

50 80 100

°C -30 -20 -10 0 10 20 30 40

5W-30

10W-30

SAE 30

Kohler PRO 10W-50

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.

°F -20 020324060

50 80 100

°C -30 -20 -10 0 10 20 30 40

5W-30

10W-30

SAE 30

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 ﬂ ammable 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

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.

STORAGE

If engine will be out of service for 2 months or more

follow 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 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 cylinder(s). Replace

spark plug(s) and crank engine slowly to distribute

oil.

3. Disconnect negative (-) battery cable.

4. Store engine in a clean, dry place.

5

Speciﬁ cations

17 690 14 Rev. E KohlerEngines.com

Engine Dimensions with Quad-CleanTM Air Cleaner and Fuel Tank-Cylinder Head Side

F

E

G

H

I

K

A

B

D

C

J

L

M

N

O

P

Q

R

A157.9 mm (6.22 in.) B108.0 mm (4.25 in.) CCylinder Center Line D238.3 mm (9.38 in.)

ESpark Plug FWiring Harness GECU H2 X Ø 11.25 mm

(0.44 in.)

IOil Drain Plug J6.0 mm (0.24 in.) K103 mm (4.06 in.) L73.8 mm (2.91 in.)

M2 X 33.0 mm

(1.30 in.) N17.0 mm (0.67 in.) O

2 X Ø 11.0 mm

(0.43 in.) X 28.0 mm

(1.10 in.) Slot

P2 X 10.5 mm

(0.41 in.)

Q57.0 mm (2.25 in.) RPTO Mounting

Surface

6

Speciﬁ cations

KohlerEngines.com 17 690 14 Rev. E

Engine Dimensions with Quad-CleanTM Air Cleaner and Fuel Tank-Flywheel Side

F

E

G

H

I

K

A

B

D

C

J

A

12.5 mm (0.49 in.)

Fuel Tank Cap

Removal

BFuel Tank C466.17 mm (18.35 in.) DCrankshaft Center

Line

E133.5 mm (5.26 in.) FCrankshaft Center

Line G195.5 mm (7.70 in.) H105.0 mm (4.13 in.)

I456.8 mm (17.98 in.) JAir Cleaner K

125.0 mm (4.92 in.)

Air Cleaner Cover

Removal

7

Speciﬁ cations

17 690 14 Rev. E KohlerEngines.com

Engine Dimensions with Quad-CleanTM Air Cleaner and Fuel Tank-Top Side

A

B

C

A493.0 mm (19.41 in.) B195.6 mm (7.70 in.) C

498.2 mm (19.62 in.)

8

Speciﬁ cations

KohlerEngines.com 17 690 14 Rev. E

Engine Dimensions with Quad-CleanTM Air Cleaner and Fuel Tank-PTO Side

G

F

H

I

J

B

C

E

D

K

B

D

EA

ADipstick and Oil Fill

Tube B35.0 mm (1.38 in.) C

4 X M8 X 1.25-6H

18.00 mm

(0.71 in.) Deep

D45°

E30° F4 X 45° G103.0 mm (4.06 in.) HStarter Motor

IØ 127.0 mm

(5.00 in.) JØ 165.1 mm

(6.50 in.) K

4 X M8 X 1.25-6H

20.00 mm

(0.79 in.) Deep

9

Speciﬁ cations

17 690 14 Rev. E KohlerEngines.com

Engine Dimensions with Quad-CleanTM Air Cleaner and Muﬄ er-Cylinder Head Side

F

E

G

H

I

K

A

B

D

C

J

L

M

N

O

P

Q

R

S

T

A188.4 mm (7.42 in.) B121.6 mm (4.79 in.) CCylinder Center Line D238.3 mm (9.38 in.)

EMuﬄ er FSpark Plug GWiring Harness HECU

I2 X Ø 11.25 mm

(0.44 in.) JOil Drain Plug K6.0 mm (0.24 in.) L103 mm (4.06 in.)

M74.0 mm (2.91 in.) N2 X 33.0 mm (1.30 in.) O17.0 mm (0.67 in.) P

2 X Ø 11.0 mm

(0.43 in.) X 28.0 mm

(1.10 in.) Slot

Q2 X 10.5 mm

(0.41 in.) R87.4 mm (3.44 in.) SPTO Mounting

Surface T444.3 mm (17.49 in.)

10

Speciﬁ cations

KohlerEngines.com 17 690 14 Rev. E

Engine Dimensions with Quad-CleanTM Air Cleaner and Muﬄ er-Flywheel Side

F

E

G

H

A

B

D

C

ACrankshaft Center

Line B133.5 mm (5.26 in.) CCrankshaft Center

Line D195.5 mm (7.70 in.)

E105.0 mm (4.13 in.) F456.8 mm (17.98 in.) GAir Cleaner H

125.0 mm (4.92 in.)

Air Cleaner

Cover Removal

11

Speciﬁ cations

17 690 14 Rev. E KohlerEngines.com

Engine Dimensions with Quad-CleanTM Air Cleaner and Muﬄ er-Top Side

A

B

C

A465.1 mm (18.31 in.) B165.3 mm (6.51 in.) C468.6 mm

(18.45 in.)

12

Speciﬁ cations

KohlerEngines.com 17 690 14 Rev. E

Engine Dimensions-Quad CleanTM Air Cleaner and Muﬄ er PTO Side

F

E

G

H

I

A

B

D

J

A

C

K

L

F

E

A35.0 mm (1.38 in.) BDipstick Assembly C

6 X 5/16-24 UNF-2B

Inch 18.00 mm

(0.71 in.) Deep

D103.0 mm (4.06 in.)

E45° F30° G4 X 45° HOxygen Sensor

I

4 X 3/8-16 UNC-2B

Inch 20.00 mm

(0.79 in.) Deep

JØ 127.0 mm

(5.00 in.) KØ 165.1 mm

(6.50 in.) LStarter Motor

13

Speciﬁ cations

17 690 14 Rev. E KohlerEngines.com

Engine Dimensions with Air Inlet Adapter-Cylinder Head Side

F

E

G

H

I

K

A B

D

C

J

L

M

N

O

P

Q

A105.8 mm (4.17 in.) B183.5 mm (7.23 in.) CSpark Plug DAir Inlet Adapter

EWiring Harness FECU G2 X Ø 11.25 mm

(0.44 in.) HOil Drain Plug

I103 mm (4.06 in.) J6.0 mm (0.24 in.) K17.0 mm (0.67 in.) L2 X 33.0 mm

(1.30 in.)

M73.8 mm (2.91 in.) N

2 X Ø 11.0 mm

(0.43 in.) X 28.0 mm

(1.10 in.) Slot

O2 X 10.5 mm

(0.41 in.) P55.7 mm (2.19 in.)

QPTO Mounting

Surface

14

Speciﬁ cations

KohlerEngines.com 17 690 14 Rev. E

Engine Dimensions with Air Inlet Adapter-Flywheel Side

F

E

G

H

I

K

A

B

D

C

J

L

M

A265.0 mm (10.43 in.) BDipstick and Oil FIll

Tube CAir Inlet Adapter D302.4 mm (11.91 in.)

ECrankshaft Center

Line F133.5 mm (5.26 in.) GDipstick HCrankshaft Center

Line

I105.0 mm (4.13 in.) J195.5 mm (7.70 in.) K193.2 mm (7.61 in.) L216.8 mm (8.54 in.)

M320.8 mm (12.63 in.)

15

Speciﬁ cations

17 690 14 Rev. E KohlerEngines.com

Engine Dimensions with Air Inlet Adapter-Top Side

A

B

D

C

E

A452.7 mm (17.82 in.) B155.6 mm (6.13 in.) C482.2 mm

(18.99 in.) DBlower Housing

EValve Cover

16

Speciﬁ cations

KohlerEngines.com 17 690 14 Rev. E

Engine Dimensions with Air Inlet Adapter-PTO Side

F

E

G

H

I

A

B

D

J

A

C

E

F

A35.0 mm (1.38 in.) BDipstick and

Oil Fill Tube C

6 X M8 X 1.25-6H

18.00 mm

(0.71 in.) Deep

D103.0 mm (4.06 in.)

E45° F30° G4 X 45° H

4 X M8 X 1.25-6H

20.00 mm

(0.79 in.) Deep

IØ 127.0 mm

(5.00 in.) JØ 165.1 mm

(6.50 in.)

17

Speciﬁ cations

17 690 14 Rev. E KohlerEngines.com

Engine Dimensions with Low-Proﬁ le Air Cleaner and ECH440LE Muﬄ er-Cylinder Head Side

F

E

G

A

B

D

C

A343.1 mm (13.51 in.) B

2 X Ø 11.0 mm

(0.43 in.) X 28.0 mm

(1.10 in.) Slot

C73.8 mm (2.91 in.) D17.0 mm (0.67 in.)

E106.8 mm (4.21 in.) F176.8 mm (6.96 in.) G2 X Ø 11.25 mm

(0.44 in.)

18

Speciﬁ cations

KohlerEngines.com 17 690 14 Rev. E

Engine Dimensions with Low-Proﬁ le Air Cleaner and ECH440LE Muﬄ er-Top Side

F

E

A

B

D

C

A305.7 mm (12.03 in.) B299.6 mm (11.79 in.) C404.6 mm (15.93

in.) D329.9 mm (12.99 in.)

E317.2 mm (12.49 in.) F422.3 mm (16.63 in.)

19

Speciﬁ cations

17 690 14 Rev. E KohlerEngines.com

Engine Dimensions with Low-Proﬁ le Air Cleaner and ECH440LE Muﬄ er-PTO Side

G

F

HI

J

B

C

M

N

K

L

D

E

A

A313.2 mm (12.33 in.) B35.0 mm (1.38 in.) C70.0 mm (2.76 in.) D133.5 mm (5.26 in.)

E

Metric Flange: 6 X M8 X

1.25-6H 18.00 mm

(0.71 in.) Deep

SAE B Flange: 6 X

5/16-24 UNF-2B Inch

18.00 mm (0.71 in.)

Deep

F195.5 mm (7.70 in.) G105.0 mm (4.13 in.) H4 X 45°

I

4 X 3/8-16 UNC-2B Inch

18.0 mm (0.71 in.)

Deep

JØ 127.0 mm

(5.00 in.) K265.1 mm (10.44 in.) LØ 165.1 mm

(6.50 in.)

M2 X 30° N103.0 mm (4.06 in.)

20

Speciﬁ cations

KohlerEngines.com 17 690 14 Rev. E

ENGINE IDENTIFICATION NUMBERS

Kohler engine identiﬁ cation numbers (model, speciﬁ cation and serial) should be referenced for eﬃ cient repair,

ordering correct parts, and engine replacement.

Model . . . . . . . . . . . . . . . . . . . . . ECH440

EFI Command Engine

Horizontal Shaft

Numerical Designation

Speciﬁ cation . . . . . . . . . . . . . . . ECH440-3001

Serial . . . . . . . . . . . . . . . . . . . . . 5023500328

Year Manufactured Code Factory Code

Code Year

50 2020

51 2021

52 2022

GENERAL SPECIFICATIONS4,5 ECH440 ECH440LE

Bore 89 mm (3.5 in.)

Stroke 69 mm (2.7 in.)

Displacement 429 cc (26.2 cu. in.)

Oil Capacity (reﬁ ll) 1.1 L (1.16 U.S. qt.)

Maximum Angle of Operation (@ full oil level)625°

TORQUE SEQUENCES ECH440 ECH440LE

(Refer to Torque Speciﬁ cations for torque values).

Closure Plate

5

1

7

3

6

2

4

Cylinder Head

1

4

2

3

4 Values are in Metric units. Values in parentheses are English equivalents.

5 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.

6 Exceeding maximum angle of operation may cause engine damage from insuﬃ cient lubrication.

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Kohler ECH440 User manual

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