Section 7 Troubleshooting; General - Kohler 4EOZ Service

7.1 General

When troubles occur, do not overlook simple causes.
Improper fuel or an empty fuel tank could cause a
starting problem. The following charts indicates some
common problems. Consult the safety precaution
section of this manual before servicing the generator
set. If the procedures in this manual do not explain how
Problem
Unit will not crank
Unit cranks but will not start
Engine starts but does not
continue to run after start switch
is released
TP-6137 5/03
Possible Cause
Weak or dead battery.
Reversed or poor battery connections.
Poor ground.
Circuit breaker tripped in the controller.
Inoperative start/stop switch.
Inoperative starter solenoid.
Inoperative starter.
Fault shutdown.
Out of fuel.
Fuel shut-off valve closed.
Inoperative fuel feed pump.
Clogged fuel filter.
Air in the fuel system.
Water or dirt in the fuel system.
Dirty or faulty fuel injectors.
Incorrect compression.
Incorrect fuel type.
Incorrect lube oil type for ambient
temperature.
Faulty fuel solenoid.
Air intake screen clogged.
Faulty ground (--) connection.
Weak or dead battery.
Engine malfunction.
Inoperative high exhaust temperature
(HET), low oil pressure (LOP), and/or high
water temperature (HWT) shutdown
switch(es).
No/low oil pressure.
No generator output voltage.

Section 7 Troubleshooting

to correct the problem, bring the generator set to an
authorized Kohler distributor or dealer.
distributor or dealer exactly what happened when the
problem occurred and any adjustments made to the
generator set.
Recharge or replace the battery.
Check the connections.
Reset the circuit breaker.
Check function; replace as necessary.
Check the starter solenoid and wiring.
Replace as necessary.
Attempt starting by direct connection to the
battery. Repair/replace as necessary.
Check the shutdown switches.
Replenish fuel supply.
Open the fuel shut-off valve.
Replace the fuel feed pump.
Service the fuel filter element.
Bleed the air.
Drain and flush the fuel system.
Contact your local Kohler generator set
distributor for service.
Contact your local Kohler generator set
distributor for service.
Use the correct fuel type. Consult the fuel
supplier.
Use the correct lube oil.
Replace the solenoid.
Clean or replace.
Clean and retighten.
Recharge or replace.
Contact your local Kohler generator set
distributor for service.
Check the HET, LOP and/or HWT
shutdown switch(es).
Check the oil pressure and pump.
Check the AC voltage.
Tell the
Corrective Action
Section 7 Troubleshooting 37