Kohler Command Pro CH260, CH270, CH395, CH440 Engine Service Repair Workshop Manual

1 17 690 01 Rev. L KohlerEngines.com CH245-CH440 Service Manual 2 Safety 3 Maintenance 5 Speciﬁcations 19 Tools and Aids 22 Troubleshooting 26 Air Cleaner/Intake 28 Fuel System 32 Governor System 42 Lubrication System 43 Electrical System 50 Starter System 55 Gear Reduction System 68 Disassembly/Inspection and Service 89 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 01 Rev. L 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 fires and severe burns. Do not fill 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 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 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 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 Cleaning Solvents can cause severe injury or death. Use only in well ventilated areas away from ignition sources. Carburetor cleaners and solvents are extremely flammable. 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 flywheel. 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 01 Rev. L 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 first 5 Hours ● Change engine oil (NOT required if using KOHLER PRO 10W-50 full-synthetic oil). Lubrication System Every 8 Hours ● Check oil bath air cleaner oil level in oil reservoir cup (if equipped). Air Cleaner/Intake Every 50 Hours ● Change oil in 2:1 with Clutch Reduction System (CH245, CH255, CH270, CH395, CH440). Gear Reduction System Every 50 Hours¹ ● Service/replace oil bath air cleaner foam filter or foam elements (if equipped). Air Cleaner/Intake Every 50 Hours or Annually (whichever comes first) ● Service/replace Quad-Clean ™ precleaner. Air Cleaner/Intake Every 100 Hours or Annually¹ (whichever comes first) ● Clean low-profile air cleaner element. Air Cleaner/Intake ● Change engine 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-profile air cleaner element. Air Cleaner/Intake ● Check fuel filters (tank outlet filter and in-line filter) clean or replace if needed (if equipped). Fuel System ● Change oil in 6:1 Reduction System (CH245, CH255, CH270). Gear Reduction System Every 300 Hours² ● Check and adjust valve clearance when engine is cold. Reassembly Every 300 Hours³ ● Change engine oil (KOHLER PRO 10W-50 oil only). Lubrication System Every 500 Hours or Annually¹ (whichever comes first) ● 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 find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

4 Maintenance KohlerEngines.com 17 690 01 Rev. L OIL RECOMMENDATIONS All-season KOHLER ® PRO 10W-50 Synthetic Oil is the ideal oil for KOHLER engines. It is specifically 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. °F -20 0 20 32 40 60 50 80 100 °C -30 -20 -10 0 10 20 30 40 5W-30 10W-30 SAE 30 Kohler PRO 10W-50 FUEL RECOMMENDATIONS WARNING Explosive Fuel can cause fires and severe burns. Do not fill 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 ignition. Never use gasoline as a cleaning agent. NOTE: E15, E20 and E85 are NOT approved and should NOT be used; effects 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 overfill 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 Speciﬁcations 17 690 01 Rev. L KohlerEngines.com CH245/CH255 Engine Dimensions Gas Cap Removal 12.50 (0.492) 88.30 (3.476) 317.62 (12.505) 29.70 (1.169) 106.00 (4.173) 358.46 (14.113) 65.05 (2.561) 32.53 (1.281) 32.53 (1.281) 65.05 (2.561) 162.0 (6.378) 66.0 (2.598) 243.55 (9.589) 307.84 (12.120) 342.71 (13.492) 113.79 (4.480) 80.0 (3.150) AIR CLEANER COVER REMOVAL 80.25 (3.159) 40.16 (1.581) 35.97 (1.416) 4.50 (0.177) 2.96 (0.116) M10 OIL DRAIN PLUG METRIC FLANGE: M8 X 1.25-6H THRU SAE A FLANGE: 5/16-24 UNF-2B THRU 2X Ø 10.00 (0.394) 2X Ø 10.00 (0.394) X 15.00 (0.610) SLOT CYLINDER CENTER LINE METRIC FLANGE: 4X M8 X 1.25-6H 15 SAE A FLANGE: 4X 5/16-24 UNF-2B 15 Dimensions in millimeters. Inch equivalents shown in [ ].

6 Speciﬁcations KohlerEngines.com 17 690 01 Rev. L CH260/CH270 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

7 Speciﬁcations 17 690 01 Rev. L KohlerEngines.com CH260/CH270 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

8 Speciﬁcations KohlerEngines.com 17 690 01 Rev. L CH395 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

9 Speciﬁcations 17 690 01 Rev. L KohlerEngines.com CH395 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

10 Speciﬁcations KohlerEngines.com 17 690 01 Rev. L CH440 Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ].

Kohler Command Pro CH260, CH270, CH395, CH440 Engine Service Repair Workshop Manual

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