CH260-CH440 Service Manual - Kohler Engines

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Electrical SystemWiring Diagram-10/18 Amp Charging System, with Rectifier-RegulatorADCBGJIKEFHA Rectifier-Regulator B Stator C Ignition Module D Spark PlugE Oil Float Switch F Oil Control Module G Key Switch H Starter MotorI Relay J Battery Fuse K 12 Volt Battery38KohlerEngines.com17 690 01 Rev. E
Starter SystemNOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period betweenstarting 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), enginerotation must be allowed to come to a complete stop before attempting to restart engine. If starter is engageswhile flywheel is rotating, starter pinion and flywheel ring gear may clash, resulting in damage of starter.NOTE: If starter does not crank engine, shut off starter immediately. Check condition of inline fuse and do not makefurther attempts to start engine until condition is corrected.NOTE: Do not drop starter or strike starter housing. Doing so can damage starter.Engines in this series use inertia drive electric starters or retractable starters. Inertia drive electric starters are notserviceable.Troubleshooting-Starting DifficultiesCondition Possible Cause ConclusionStarter does not energize. Battery Check specific gravity of battery. If low, recharge or replacebattery as necessary.Wiring Check fuse condition.Clean corroded connections and tighten loose connections.Replace wires in poor condition and with frayed or brokeninsulation.Starter Switchor SolenoidCheck switch or relay operation. If starter cranks normally,replace faulty components.Starter energizes but turnsslowly.Battery Check specific gravity of battery. If low, recharge or replacebattery as necessary.Wiring Check for corroded connections, poor ground connection.TransmissionorEngineMake sure clutch or transmission is disengaged or placedin neutral. This is especially important on equipment withhydrostatic drive. Transmission must be exactly in neutral toprevent resistance which could keep engine from starting.Check for seized engine components such as bearings,connecting rod, and piston.Electric Starting System Tests1. Test battery on unit.a. Connect a DC voltmeter across battery terminalsand read battery voltage (key switch OFF).b. Turn key switch to start position and read batteryvoltage again. Turn switch OFF.ConditionVoltage less than 12 volts.Battery voltage should notfall below 9 volts duringcranking.ConclusionCharge battery.If it does, battery may befaulty or there may be ashort in starting circuit.Have battery load tested.If battery passes load test,check circuitry.2. Remove electric starter cover panel and check fuseinside plastic holder. Fuse outside holder is a spare.ConditionFuse is blown.ConclusionCheck for a wiringproblem (bare wire, shortcircuit). Correct problemand replace fuse. Try tostart engine. If it still won’tstart, go to step 3.3. Disconnect blue relay lead. Be sure transmission isin neutral and PTO is OFF. Connect one end of ajumper lead to positive terminal of battery. Connectother end to terminal of relay.ConditionRelay engages and starterbegins to crank.ConclusionKey switch is faulty, orthere is a wiring problemto/from key switch. Checkwiring and test key switchcircuits with an ohmmeter.17 690 01 Rev. E KohlerEngines.com39
Page 1 and 2: CH260-CH440Service ManualIMPORTANT:
Page 3 and 4: MaintenanceMAINTENANCE INSTRUCTIONS
Page 5 and 6: SpecificationsCH260/CH270 Engine Di
Page 7 and 8: SpecificationsCH395 Engine Dimensio
Page 9 and 10: SpecificationsCH440 Engine Dimensio
Page 11 and 12: SpecificationsENGINE IDENTIFICATION
Page 13 and 14: SpecificationsTORQUE SPECIFICATIONS
Page 15 and 16: SpecificationsCLEARANCE SPECIFICATI
Page 17 and 18: SpecificationsGENERAL TORQUE VALUES
Page 19 and 20: Tools and AidsTOOLSDescriptionHydra
Page 21 and 22: TroubleshootingTROUBLESHOOTING GUID
Page 23 and 24: TroubleshootingCRANKCASE VACUUM TES
Page 25 and 26: Air Cleaner/IntakeAIR CLEANERThese
Page 27 and 28: Fuel SystemCARBURETORWARNINGExplosi
Page 29 and 30: Fuel System● Inspect carburetor b
Page 31 and 32: Lubrication SystemThese engines use
Page 33 and 34: Electrical SystemCarbon FouledELECT
Page 35 and 36: Electrical System7. Set an ohmmeter
Page 37: Electrical System3/4/10/18 Amp Batt
Page 41 and 42: Starter SystemRETRACTABLE STARTERSW
Page 43 and 44: Disassembly/Inspection and ServiceW
Page 45 and 46: Disassembly/Inspection and ServiceC
Page 47 and 48: Disassembly/Inspection and ServiceR
Page 49 and 50: Disassembly/Inspection and ServiceV
Page 51 and 52: Disassembly/Inspection and ServiceC
Page 53 and 54: Disassembly/Inspection and ServiceR
Page 55 and 56: Disassembly/Inspection and ServiceP
Page 57 and 58: Disassembly/Inspection and ServiceH
Page 59 and 60: ReassemblyCH395/CH440 Crankshaft/Ca
Page 61 and 62: ReassemblyCH395Governor DetailsCH44
Page 63 and 64: ReassemblyCH395/CH440 Torque Sequen
Page 65 and 66: ReassemblyAssemble Cylinder HeadNOT
Page 67 and 68: ReassemblyCH395/CH440 Blower Housin
Page 69 and 70: ReassemblyCH260/CH270 Governor Leve

CH260-CH440 Service Manual - Kohler Engines

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