Kohler 3.5CFZ, 4CZ, 5CFZ, 6.5CZ Troubleshooting, Engine, Corrective Action, Unit will not crank

Section 4. Troubleshooting

When troubles occur, do not overlook simple causes. A starting problem, for example, could be caused by improper fuel or an empty fuel tank. The following charts list some common problems. If procedures in this manual do not explain how to correct the problem, take

the generator set to an authorized service dealer/distributor. Tell the dealer exactly what happened when the problem occurred and of any adjustments made to the set.

Engine

Problem	Possible Cause	Corrective Action
Unit will not crank	Weak or dead battery	Recharge or replace battery
	Reversed or poor battery connections.	Check connections
	Poor ground.
	Fuse blown in controller	Replace fuse
	Defective start/stop switch	Check function, replace as necessary.
	Defective starter solenoid	Check starter solenoid and wiring. Replace
		as necessary.

Defective starter

Attempt starting by direct connection to battery. Replace/repair as necessary.

Unit cranks but will	Out of fuel	Replenish
not start	Clogged fuel screen	Clean fuel screen
	Faulty antidieseling solenoid	Replace solenoid
	Air intake clogged	Clean or replace
	Faulty spark plug(s)	Replace (and regap) spark plug(s)
	Loose spark plug connection	Reconnect wires
	Faulty ground (--) connection	Clean and retighten
	Carburetor adjustment wrong	Adjust carburetor
	Defective electric fuel pump	Check pressure. Replace as necessary.
	Shorted or open ignition coil	Replace coil
	Weak or dead battery	Recharge or replace
	Bad fuel mixture	Replace fuel; clean carburetor
	Flooded carburetor	Wait a few minutes and attempt restart
	Engine malfunction	See authorized Kohler service
		dealer/distributor

Engine starts, but does not continue to run after start switch is released

No generator output voltage	Check AC voltage
No/low oil pressure	Check oil pressure and pump
Defective low oil pressure (LOP) safety	Check LOP shutdown switch
shutdown switch
High temperature shutdown	Check cooling system
Defective high exhaust temp. (HET) and/or	Check HET and/or HWT shutdown
high water temp. (HWT) safety shutdown	switch(es)
switch(es)

Hard starting

Stale or bad fuel	Replace fuel
Fuel vapor lock	Check fuel line routing
Faulty spark plug(s)	Replace (and regap) plug(s)
Weak ignition coil	Replace
Carburetor adjustment wrong	Adjust carburetor
Air intake clogged	Clean

TP-5695 12/93 Troubleshooting 4-1