Kohler Diesel Engine Problems: Symptoms and Best Fixes

Kohler is a manufacturer of diesel engines. Husqvarna, Dixon Chopper, Craftsman, Toro, and Westinghouse are a few of the equipment manufacturers that utilize Kohler diesel engines in their machines. Kohler diesel engines are used in devices for lawn and gardening, construction, marine, and industrial applications. Lawnmowers, generators, pumps, boats, snowblowers, saws, forklifts, and jet skis are examples of the type of machines that utilize Kohler engines.

These engines can develop faults or problems. This article takes a top view of some of the problems that you might face with a Kohler diesel engine. Also elucidated are the symptoms of and fixes for these problems.

Kohler Diesel Engine Problems, Symptoms, and Fixes

Kohler has many diesel engine series and models. Yet the engine problems discussed here are not specific to a particular one and, in a generalist approach, cover most. Engine problems discussed here include a short description of the problem, symptoms, causes, and best fixes.

Engine Not Starting

Engines need to start before you can put them to work. A Kohler engine in any type of machine can suffer from a starting problem. Specifically, we refer to the inability of a Kohler engine to start at all. Some of the symptoms of a Kohler engine starting problem include:

1) The Engine Does Not Crank

Kohler engines, like any combustion engine, should make audible cranking sounds as you try to power them on. The starter motor generates the cranking sound, and it is probably at fault for the engine not cranking or starting in this case. Otherwise, it is the battery or connection that sends power to the starter that is faulty.

2) Cranking Without Starting

In some cases, the engine will crank without the engine powering on as expected. Inadequate fuel, compression problems, blown fuse, spark plug, etc., could cause the Kohler engine to crank without starting.

3) Slow Cranking

These cranking-related symptoms must be making you cranky, but another common Kohler starting issue is slow or weak cranking without the engine starting. Causes of slow Kohler engine cranking include a weak battery, a bad connection, or a damaged starter.

4) The Engine Starts and Dies Immediately

Inadequate fuel, glow plug trouble, and injection issues are some of the things that can cause the engine to start momentarily but immediately shut down.

5) Cold Engine

Low temperatures may make it hard for a Kohler engine to generate heat for combustion. If your engine has a glow plug, there might be an issue with it.

Possible Causes

Below are some of the possible causes of a Kohler engine "Will Not Start" problem according to Kohler.

• No fuel
• Improper fuel
• Dirt in fuel line
• Incorrect oil level
• Overloaded engine
• Dirty air cleaner
• Faulty spark plug

Best Fixes

• Add fuel if fuel or oil if they are too low
• Use the recommended fuel for your particular engine
• Replace bad spark plugs, battery, or starter motor
• Clean or replace dirty or clogged fuel lines, fuel filters, and air filters

Hard Starting

No one likes a hard or difficult start to their day or task. Your engine hard starting is not great either. Diesel engines like Kohler's have designs that are supposed to simplify and ease starting compared to other combustion systems. So, a hard start is not also undesirable but is also a pointer to a possibly more significant issue in the near future. Some of the symptoms of a Kohler engine hard starting include:

1) Slow Cranking

This symptom could occur without the engine starting and can also happen with the engine grudgingly coming on. A weak battery, faulty connection, or weak starter can cause this issue.

2) Engine Smoking When Starting

Smoke coming out of the exhaust when starting a Kohler-powered machine is not expected, especially in excessive amounts. Engine smoking as you try to start a Kohler engine could be because of inadequate fuel, a cold engine, or a problem with the injection system.

3) Low Engine Power

Clogged fuel filters, low compression, misfiring cylinder, and injection system-related issues could cause the Kohler diesel engine to have low power after starting.

Possible Causes

Possible causes of Kohler engine "Hard Starting," according to Kohler, include:

• Improper fuel
• Dirt in fuel line
• Incorrect oil level
• Engine overloaded
• Dirty air cleaner
• Faulty spark plug

Best Fixes

• Replace weak batteries
• Ensure glow plugs are working
• Replace dirty fuel filters
• Inspect the cylinders, injection, and compression system for faults

Engine Misfire

An engine misfire results from inadequate combustion in at least one cylinder in the diesel engine. Some of the symptoms of a Kohler diesel engine misfire include:

1) Low Power

A misfiring cylinder reduces the power output of the Kohler engine as it is not contributing as much as it is capable of.

2) Increased Vibrations

Beyond the expected and usually mild vibrations from an operating Kohler engine, a misfiring cylinder will increase engine vibrations. Increased engine vibrations are a result of a lack of alignment in the timing of the misfiring cylinder with the others. This situation will lead to an increase in engine shakes and vibrations.

3) Increased Emissions and black smoke

Besides vibrations, a misfiring Kohler engine will also lead to an increase in emissions. Incorrectly burned fuel during combustion may be emitted as a pollutant in the form of visible black smoke.

4) Hard Starting

One of the things that can cause the Kohler diesel engine to start hard is a misfiring engine cylinder. A misfiring engine cylinder will not add to the combustion process as it should. Thus, the engine will find it harder to turn over.

Possible Causes

Kohler identifies some of the possible causes of engine "Skips or Misfires" as follows:

• Improper fuel
• Dirt in fuel line
• Dirty debris screen
• Dirty air cleaner
• Faulty spark plug

Best Fixes

• Use recommended fuel
• Replace worn or damaged fuel filters and spark plugs
• Examine the fuel injection system for issues
• Inspect and ensure the fuel pressure and compression are correct
• Repair or replace worn or damaged pistons, valves, and rings

High Fuel Consumption

A potential problem you could experience with a Kohler diesel engine is an increase in the amount of fuel it consumes. Fuel efficiency is crucial for sustained work. A spike in fuel consumption will increase the cost of using the machine and also reduce work efficiency due to frequent refills. Some of the symptoms besides increased fuel consumption include:

1) Increased smoking

A sign that your Kohler engine is no longer efficiently burning fuel is increased smoke from the exhaust.

2) Loss of Power

Another sign of reduced fuel efficiency is a reduction in power. A loss of power could result from inadequate fuel getting to the engine or inefficient combustion. One of the causes could be a leak in the fuel delivery or injection system.

3) Frequent Refills

A clear sign that the engine is using up more fuel than usual is if you discover you have to refill the fuel tank more often than you are familiar with for the same type of work.

4) Unusual Noises

Weird or unusual noses, in some cases, may have a relationship with increased fuel consumption or reduced fuel efficiency. Issues with fuel-related components like the injectors and pumps could cause strange sounds. A problem with the fuel delivery system could lead to reduced fuel efficiency.

Possible Causes

According to Kohler, some of the possible causes of "High Fuel Consumption" include:

• Engine overloaded
• Dirty Air Cleaner
• Faulty Spark Plug

Some additional causes of high fuel consumption include low pressure, fuel leaks, damaged valves or rings, and bad injectors.

Best Fixes

• Inspect the fuel pressure level
• Fixes any leaks in the fuel system
• Repair/replace failing valves and rings
• Don't overload the machine
• Use the recommended fuel
• Don't idle frequently
• Maintain the engine as recommended

Engine Overheating

An engine overheating is when its temperature rises to a level beyond its thermal limits. An overheating Kohler engine could be catastrophic for the engine's health and potentially dangerous situation for operators. Some of the symptoms include:

1) High Reading from Temperature Gauge

Unless it is damaged, the temperature gauge on a machine equipped with a Kohler engine will rise to the top. Additionally, there should be a warning light or indicator to warn operators.

2) Loss Of Power

As it gets hotter, the engine may stall or rough idle as it loses power.

3) White Smoke

An overheating engine may emit white smoke as it burns off coolant.

4) Engine Seizure

Engine seizure is when the engine's moving components freeze. This can happen without adequate oil to lubricate the moving pieces. The friction caused by inadequate lubrication can cause the engine to overheat and engine seizures. Causes include low oil, dirt, or defects.

Possible Causes

Some of the things Kohler identifies as possible causes of "Overheats" include:

• Dirt in fuel line
• Dirty debris screen
• Incorrect oil level
• Engine overloaded
• Dirty air cleaner

Best Fixes

• If in operation, move the equipment to a safe location, shut off the engine, and let it cool.
• Inspect the coolant if it is low and replenish it if necessary
• Add engine oil if it is below the recommended threshold
• Check for leaks and repair/replace where necessary
• Repair/replace a damaged thermostat
• Clean dirty air cleaners
• Get a professional inspection of the Kohler engine
• Perform regular maintenance of the Kohler engine to prevent overheating

Conclusion

This article set out to identify some common Kohler diesel engine problems. In identifying these problems, we listed their symptoms, causes, and best fixes. Some of the issues highlighted include engine not starting, hard starts, and misfires. Also identified were high fuel consumption and engine overheating. If you have a Kohler engine, you should be mindful of these problems and their symptoms, so you can address them before they devolve into something worse.

The Kohler diesel engine problems identified are not exhaustive; there are others. However, whatever it may be, you can prevent Kohler engine problems with regular inspection, maintenance, and correct operation of the engine and machine it is fitted in.