EN DA CH260, CH270, CH395, CH440 Owner's Manual DE ESE ESS FRC FRF HR ID IT NL PL PT RO RU SL ZH 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 you specific rights and obligations. Record engine information to reference when ordering parts or obtaining warranty coverage. Engine Model Specification Serial Number Purchase Date 17 590 11 Rev. -- KohlerEngines.com 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 Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. 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 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. CAUTION Electrical Shock can cause injury. Do not touch wires while engine is running. 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. California Proposition 65 Warning Engine exhaust from this product contains chemicals known to State of California to cause cancer, birth defects, or other reproductive harm. 2 KohlerEngines.com 17 590 11 Rev. -- EN E S Q B B A C F R P D O A G E H M N L I J A E I M Q Air Cleaner Cover Air Cleaner Base Starter Handle On/Off Switch (if equipped) Low-Profile Air Cleaner B F J N R Bail Quad-CleanTM Air Cleaner Retractable Starter Throttle Lever Screw C G K O S Precleaner Choke Lever Oil Drain Plug Fuel Tank Foam Element D H L P K Paper Element Fuel Shut-Off Dipstick/Oil Fill Plug Fuel Cap Pre-Start Checklist 1. Check oil level. Add oil if low. Do not overfill. 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 components and all shrouds, equipment covers, and guards are in place and securely fastened. 5. Check spark arrestor (if equipped). 17 590 11 Rev. -- KohlerEngines.com 3 Starting WARNING Carbon Monoxide can cause severe nausea, fainting or death. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled. 4. Retractable Start: Slowly pull starter handle until just past compression-STOP! Return starter handle; firmly 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. 5. Gradually return choke control to OFF position after engine starts and warms up. Engine/equipment may be operated during warm up period, but it may be necessary to leave choke partially on until engine warms up. Cold Weather Starting Hints 1. Use proper oil for 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 maximum angle of operation; see specification table. Engine damage could result from insufficient lubrication. Engine Speed NOTE: Do not tamper with governor setting to increase maximum engine speed. Overspeed is hazardous and will void warranty. High Altitude Operation This engine may require a high altitude carburetor kit to ensure correct engine operation at altitudes above 4000 ft. (1219 meters). To obtain high altitude kit information or to find a Kohler authorized dealer KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). This engine should be operated in its original configuration below 4000 ft. (1219 meters) as damage may occur if high altitude carburetor kit is installed and operated below 4000 ft. (1219 meters). 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. NOTE: Choke position for starting may vary depending upon temperature and other factors. Once engine is running and warm, turn choke to OFF position. NOTE: Extend starter cord periodically to check its condition. If cord is frayed have it replaced immediately by a Kohler authorized dealer. NOTE: Do not crank 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. NOTE: If engine develops sufficient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine. If starter is engaged while flywheel is rotating, starter pinion and flywheel ring gear may clash, resulting in damage to 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: Cold engine: Place throttle control midway between SLOW and FAST positions. Place choke control into ON position. Warm engine: Place throttle control midway between SLOW and FAST positions. Return choke to OFF position as soon as engine starts. A warm engine usually does not require choke on. 4 KohlerEngines.com 17 590 11 Rev. -- Carburetor Icing NOTE: Running engine with cover positioned for cold weather operation in normal conditions can damage engine. Carburetor icing can take place when certain combinations of temperature and humidity exist. Result of carburetor icing is rough running at idle or low speed as well as black or white smoke. To reduce likelihood of carburetor icing, air cleaner cover can be rotated to draw warmer air from muffler side. For cold weather operation, position air cleaner cover with snowflake decal out. For normal operation, position air cleaner cover with sun decal out. Maintenance Instructions EN 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 After first 5 Hours Change oil. Every 50 Hours or Annually Service/replace Quad-CleanTM precleaner. Every 100 Hours or Annually¹ Clean low-profile air cleaner element. Change oil. Clean cooling areas. Replace spark plug and set gap. Every 200 Hours² Check and adjust valve clearance when engine is cold. Every 200 Hours Replace Quad-CleanTM air cleaner element. Every 300 Hours Replace low-profile air cleaner element. Check fuel filters (tank outlet filter and in-line filter) and clean or replace if needed (if equipped). 1 Perform these procedures more frequently under severe, dusty, dirty conditions. 2 Have a Kohler authorized dealer perform this service. Check Oil Level NOTE: To prevent extensive engine wear or damage, never run engine with oil level below or above operating range indicator on dipstick. Ensure engine is cool. Clean oil fill/dipstick areas of any debris. 1. Remove dipstick; wipe oil off. 10W-30 SAE 30 5W-30 Oil Recommendations We recommend use of Kohler oils for best performance. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below. 2. Reinsert dipstick into tube; rest on oil fill neck; turn counterclockwise until cap drops down to lowest point of thread leads; do not thread cap onto tube. 100 40 °F -20 °C -30 -20 0 -10 20 32 0 40 50 10 60 20 80 30 17 590 11 Rev. -- KohlerEngines.com 5 a. Remove dipstick; check oil level. Level should be at top of indicator on dipstick. or b. Remove oil fill plug. Level should be up to point of overflowing filler neck. 3. If oil is low, add oil up to point of overflowing filler neck. 4. Reinstall dipstick or oil fill plug and tighten securely. Change Oil Change oil while engine is warm. 1. Clean area around oil fill cap/dipstick and drain plug. 2. Remove drain plug and oil fill cap/dipstick. Drain oil completely. 3. Reinstall drain plug. Torque to 13 ft. lb. (17.6 N·m). 4. Fill crankcase with new oil, up to point of overflowing filler neck. 5. Reinstall oil fill cap/dipstick and tighten securely. 6. Dispose of used oil in accordance with local ordinances. Oil SentryTM (if equipped) This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil SentryTM 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 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. Add Fuel 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. Ensure engine is cool. 1. Clean area around fuel cap. 2. Remove fuel cap. Fill to base of filler neck. Do not overfill fuel tank. Leave room for fuel to expand. 3. Reinstall fuel cap and tighten securely. Fuel Line 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. Low permeation fuel line must be installed on carbureted Kohler Co. engines to maintain EPA and CARB regulatory compliance. Fuel Valve Engines are equipped with a fuel valve and integral screen filter located at inlet of carburetor. It controls and filters fuel flow from tank to carburetor. Clean fuel valve cup of debris. 1. Remove two nuts, two screws, and carburetor cover panel. 2. Turn fuel valve lever to OFF positio ...