Cold Starting Kohler 5E

jason78

jason78

Active Member
TECHNICAL Contributor
Sep 3, 2008
3,662
Fort Mill, SC / Lake Wylie
Boat Info
1997 20 Outrage
Engines
200 Merc Offshore
I have a Kohler 5E that only has about 87 hours on it. This thing is really starting to get on my nerves with it's intermittent starting problems. I just want to confirm I AM starting it the right way.

Turn on blowers, press "ON" Generator Switch (solid blue light comes on that switch), them press and hold "START" until Blue light on "START" switch comes on. Up to this point I have not tried to press or hold down the "STOP/PREHEAT" switch before starting. Sometimes it starts right up and runs like a champ, sometimes it will act like it is starting and die. Once it has decided it will not start, that is it for the day.

I ask this because there is NO mention of using the "STOP/PREHEAT" switch anywhere in any of the manuals.

Also, while we are on this topic- To turn off the Generator, what do I do first? Switch the "ON" button the other way or press the "STOP/PREHEAT" button? The manual does not give clear instructions on this either.

This is a factory installed 5E. My remote panel has 3 switches. "BLOWER", "ON" and another switch with "START" at the top and "STOP/PREHEAT" at the bottom.

So far the following has been done to troubleshoot this problem. New Spark Plugs, New Fuel Filters, New Impeller Kit.

Thanks
Jason
 
New Spark Plugs,
Click to expand...
I've never heard of a Preheater on a gas engine before. :huh:. There's got to be a electric choke switch some wheres. Yes??
 
Mine is a Westerbeke 4.5 and it has three switches, Blower, Start, and Pre-Heat.

The pre-heat must just be printed for a diesel genny, but mine is gas and on the gas model this switch when depressed activates and electric fuel pump and the choke. As you depress it with the ER hatch open, you can hear the click of the choke going on and off as the switch is pushed and let go.

Try pressing and holding this switch for 10 seconds and while still depressing it, hit the start button. It also helps to have someone try the switch while you listen and watch the genny to see what is happening.
 
burwellj78 said:
I have a Kohler 5E that only has about 87 hours on it. This thing is really starting to get on my nerves with it's intermittent starting problems. I just want to confirm I AM starting it the right way.

Turn on blowers, press "ON" Generator Switch (solid blue light comes on that switch), them press and hold "START" until Blue light on "START" switch comes on. Up to this point I have not tried to press or hold down the "STOP/PREHEAT" switch before starting. Sometimes it starts right up and runs like a champ, sometimes it will act like it is starting and die. Once it has decided it will not start, that is it for the day.

I ask this because there is NO mention of using the "STOP/PREHEAT" switch anywhere in any of the manuals.

Also, while we are on this topic- To turn off the Generator, what do I do first? Switch the "ON" button the other way or press the "STOP/PREHEAT" button? The manual does not give clear instructions on this either.

This is a factory installed 5E. My remote panel has 3 switches. "BLOWER", "ON" and another switch with "START" at the top and "STOP/PREHEAT" at the bottom.

So far the following has been done to troubleshoot this problem. New Spark Plugs, New Fuel Filters, New Impeller Kit.

Thanks
Jason
Click to expand...

One thing that puzzles me... are you saying that one of your switches is labled "STOP/PREHEAT"?
 
Well, that rules out holding the pre-heat while hitting the start button. :smt021

I'd still take a good look at the genny when all is quiet and have someone press the stop/pre-heat button and see if anything is happening.

If that fails, you may just have to read the owner's manual!:grin:
 
Jimmy Buoy said:
If that fails, you may just have to read the owner's manual!:grin:
Click to expand...

Normally I would count on the manual for this info but I have read all Kohler documentation and there is no mention of the Preheat function or even an "ON" button for that matter. :huh:
 
Last edited:
Have the choke assembly adjusted. Once mine was adjusted, it starts right up. Hot or cold.

The preheat button heats a very small coil in the choke assembly. It wont work well if the choke is not set close...
 
Jason,

My 5E has 96 hours as of today. It hasn't run in 16 days, and my bilge temp was 44 degrees. It started after 10 seconds of cranking (BTW - that is the limit for cranking with the seacock open - if no start, wait 60 seconds, close the seacock and crank again for 10 seconds - if no start, wait 60 more seconds and crank again for 10 seconds. Open the seacock when it starts). That's out of section 2.6 in the owner's manual. I know that doesn't help you at all so far, but I wanted you to know what mine is doing.

The preheat does not do anything on our gennys as far as I can tell. I've held it in prior to start for 10 seconds, and it does not seem to make a difference. I have found that I need to hold the start button depressed for about 3-4 seconds after it cranks up to keep it running.

Since you have new plugs, fuel filter and impeller, I would attempt to adjust your choke. Spray the linkage with some white lithium grease, and note where the electric choke is set - there are a couple of screws that can be loosened and the choke rotated to increase or decrease it's effect. The two power wires for the choke heater are on top of the black choke disc that you would rotate. Check your flame arrestor for clogging, and maybe spray some carb cleaner "down the throat" (I use Chemtool B-12).

The Kohler Owner's Manual (TP-5985) and Service Manual (TP-5986) are very inadequate when it comes to these problems. They are about 2 MB is size, and if you don't have them, PM me and I will be glad to email them to you.

Sorry I'm not much help. I try to run mine every 10-14 days or so and I run it loaded after a 4 minute warm-up (A/C, water heater, and cockpit heater usually load it to 35 amps). The manual says run it for an hour once a week. For the past year a half hour every two weeks has worked for me.

My dockmate Windjammer (on this forum) is having some starting problems with his 5E, so maybe he can chime in.
 
The "preheat" function on the WB 4.5 acts as an electric choke and also activates the fuel pump to bring fuel to the float bowl if it is empty. I have to play with mine a little to get a clean start when it is cold (i.e. has not been run in several weeks). I would imagine the Kohler has a similar function. I would hold the button down in the Stop/Preheat area first for 10-15 seconds, then try and start. Never seen one labeled as Stop/Preheat on the same side of the switch though. Strange....
 
When starting remotely (i.e. cabin panel), engine starts but dies after a few seconds - only started doing this when the weather got colder.
Last time this happened (last week), tried starting from the unit itself and "jiggled" the choke linkage while pressing the start button. Fired right up and stayed running, so I feel it is the choke that is causing the problem. Either some adjustment is needed or the thermostat coil is shot. I may just replace the whole "choke heater assembly" - Kohler P/N 359356 - cost is about $52.00...
 
beachcombersc said:
Have the choke assembly adjusted. Once mine was adjusted, it starts right up. Hot or cold.

The preheat button heats a very small coil in the choke assembly. It wont work well if the choke is not set close...
Click to expand...

+1. Easy to adjust and it is most the problem. I have a post and a picture of the choke assy and how to adjust somewhere on CSR.
 
The "pre heat" is typically for a diesel. The Kohler 5E has an automatic.

This type of choke assembly has basicly 3 parts: a coil spring, pull off and heater. The choke coil spring closes the choke plate when cold. As soon as the engine starts, the pull off cracks open the choke plate so the engine can breath and not flood out. The heater warms up the coil spring when the engine is running as so the choke plate will continue to open up fully as the engine warms up.

Service this choke assembly by noting the index setting and pulling off the cover. Use carb cleaner to clean up the pull off plunger. Make sure the vacuum sorce to the choke group is ok. Clean up the choke plate at carb with carb cleaner. Put all back together and get running (you may have to hold choke open to get started with all that carb cleaner in there). After cools down try again and adjust the choke index setting if needed. Your better off a little lean as where it starts, runs and dies once rather than starts, floods and then wont restart till it dries out. ...Ron

Check this out too. http://www.marinegenerators.us/kohler/lit/TP5986.PDF
 
BonBini said:
The "pre heat" is typically for a diesel. The Kohler 5E has an automatic.

This type of choke assembly has basicly 3 parts: a coil spring, pull off and heater. The choke coil spring closes the choke plate when cold. As soon as the engine starts, the pull off cracks open the choke plate so the engine can breath and not flood out. The heater warms up the coil spring when the engine is running as so the choke plate will continue to open up fully as the engine warms up.

Service this choke assembly by noting the index setting and pulling off the cover. Use carb cleaner to clean up the pull off plunger. Make sure the vacuum sorce to the choke group is ok. Clean up the choke plate at carb with carb cleaner. Put all back together and get running (you may have to hold choke open to get started with all that carb cleaner in there). After cools down try again and adjust the choke index setting if needed. Your better off a little lean as where it starts, runs and dies once rather than starts, floods and then wont restart till it dries out. ...Ron

Check this out too. http://www.marinegenerators.us/kohler/lit/TP5986.PDF
Click to expand...

At that site, you will find both the Owner's Manual (TP-5985) and Service Manual (TP-5986) as well as the Part's Manual (TP-5987) for the 5E as well as others...
 
BonBini said:
The "pre heat" is typically for a diesel. The Kohler 5E has an automatic...
Click to expand...

According to my 320 manual there is a "Preheat/On" toggle on the Cabin Main DC distribution panel. This button is supposed to be held down simultaneously with the generator start button and is to be held down for 2-3 seconds after the generator starts. The manual explains its purpose as follows: "This bypasses the Low Oil Pressure shutdown sensor utill the generator oil pressure rises to its normal running pressure." I am assuming the panels on our boats are similar. If not, disregard my post since it most likely does not apply to your 280.:huh:
 
Bob,

On my 340, with a 5E, it is physically impossible to hold the PREHEAT/STOP switch and START switch at the same time. They are both located on opposite ends of the same rocker switch.
 
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