Kohler Generator Diesel 8K

Audrey II

Audrey II

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Aug 5, 2008
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I'm having a problem with my genny it was working fine and suddenly shut down. I check oil and it was fine, I checked the water flow it too was fine. It would start and then stall but then it failed to even starting which lead me to believe it's a fuel problem not a safety switch. I replaced both the recor filter and the spin on and still nothing. I don't know it the fuel pump is working I'm not getting flow to the injectors. I checked for power at the fuel pump and it seems very low to me I was expecting 12 volts but it was more like 5 volts I don't know if this is normal. I can't find any info in the manual the diagram doesn't show voltage. I didn't have the book with me when I was there today but I have it know and I will return tomorrow to try to bleed the system if the pump is actually working but I have my doubts.

So the big question is, is the voltage the problem or is the pump not working or third is there an air lock that I will need to bleed out.

Any thoughts welcome.
 
You should get at least 12 volts at the pump
when working. Check your connections and
make sure the pump gets the voltage it needs.
Good Luck,
H
 
If it is a 12 volt pump then there must be a safety switch inline somewhere that it preventing proper voltage. I have 13 volt at the solenoid. This may be an issue being I have limited access to the genny to follow the wiring. I may have to get some help on the one. I really hate not being able to fix things myself more then just the money I like to trouble shoot and learn while making repairs. I'm heading back today to try to figure this out, I guess if I can't I'll call a pro.
 
A safety switch would produce zero volts down stream. A bad connection will produce less then normal volts e.g. 5V
 
a bad switch caused a similar problem for me.

New switch gave me the proper voltage and away we went!

RWS
 
Not real familar with Kohlers but with an electric fuel pump there likely is an oil pressure switch in the power circuit to the fuel pump. Find it, bypass it then see if runs. Don't leave it bypassed though - replace the oil pressure switch
 
I went back to the boat today and did some more testing the pump is not getting power at all. I feed the pump power and got good flow and it will start but not stay running they is some sensor or control module preventing it from working. The oil and temp sensors are all tied together and feed a ground to shut down the motor. The sensors are bypass during the start up but the motor dies out before I even let go of the start button. I have tested the sensors and they seem to be OK the temp are open and the pressure is close with the motor off, I disconnected the oil sensor just in case and it made no difference. I'm at a loss I did notice a couple of connectors get real hot during the start up but the wire before and after stayed cool this led me to believe the connections were bad so I replaced them and now the stay cool but it didn't help it start. I also noticed the the fuel solenoid gets real hot as well I'm not sure why but I probably would cool as soon as I release the start button.

Any thoughts are welcome, I guess will have to drop it off with Boatingcomfort to look at it I just hate not being able to figure things like this out myself.
 
i dont know anything about your moderl but my gas kohler if the relays dont see 120 volts engine shuts off when you release starter. i found copies of the service manual on web there are flow sheets to help you troubleshoot
 
This is actually shutting down before I let go of the start button. In addition whatever is causing the problem is also preventing power from getting to the fuel pump.
 
you should find service manual here marinegenerators.us/kohler looking at flow sheet if your genny is 8eoz its a relay or board or generator is not producing 120v and is shutting down need to follow all steps in flow diagrams hope that helps
 
Problem solved corroded wire in control box. All fixed and only cost about 5 cents to repair.
 
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