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Author Topic: Down in the Dumps with my Kohler Engine / Not fixed / FIXED!  (Read 59088 times)

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Offline POSTON WIDEHEAD

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Down in the Dumps with my Kohler Engine / Not fixed / FIXED!
« on: March 02, 2016, 07:16:02 PM »
I am about to pull my hair out over my Kohler engine.
It got to skipping and losing power about 3-4 weeks ago.
It would crank and idle perfect. Engage the blade and it would die.

The engine has 1100 hours on it.
Never been in the rain.

Things I have done:

I have had discussions with Woodmizer Indy, Albemarle, N.C. and Kohler.
I have tried everything we discussed.

1. Brand new gas tank installed.
2. Brand new male and female connections from mill to gas tank
3. Brand new fuel lines throughout and new clamps
4. Brand new fuel filters from Kohler
5. Brand new fuel pump from Kohler
6. Brand new spark plugs recommended by Kohler and Woodmizer
7. Brand new plug wires
8. Brand new 02 Censor
9. Brand new Non-ethanol gas
10. Ran Sea-Foam through engine
11. Brand New Inner and outer air filters.

Now the engine runs 98% perfect.

As it stands now.....it cranks perfect and idles perfect.
I can engage the clutch and NO power lost.....acts just like a new engine.

NOW.....when the engine is running and the blade is engaged and its at full RPM's you would think it is perfect.
However, when I hydraulic the back stops up......the engine starts to sputter and finally begins to run right.
When I engage the blade, a puff of smoke comes out and I can smell gas in that puff of smoke....it then goes away.

The engine a 29hp (printed on engine) which legally is now defined as a 26hp.
It is EFI.

I am NOT losing any production cutting wood.....it saws fine.
Sometime when the blade enters a log, it will sputter a little.

This problem is driving me bonkers!

I thought I would check with you guys before pulling the engine and taking it to Kohler in Charlotte, N.C.


The older I get I wish my body could Re-Gen.

Offline Ohio_Bill

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Re: Down in the Dumps with my Kohler Engine
« Reply #1 on: March 02, 2016, 07:23:03 PM »
Air Filter  ?  Maybe
Bill
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Offline sandsawmill14

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Re: Down in the Dumps with my Kohler Engine
« Reply #2 on: March 02, 2016, 07:27:24 PM »
i dont know but i would bet if you take the engine off and take it to them it will run perfect while they check and tell you the engine is fine >:( at least thats the luck i have :)
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Offline sawguy21

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Re: Down in the Dumps with my Kohler Engine
« Reply #3 on: March 02, 2016, 07:29:09 PM »
I would run it with an inline spark tester on each plug. If the spark is steady as the engine falters look for debris in the carburetor high speed circuit, it comes into play when load is applied and the throttle is wide open.
old age and treachery will always overcome youth and enthusiasm

Offline drobertson

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Re: Down in the Dumps with my Kohler Engine
« Reply #4 on: March 02, 2016, 07:30:37 PM »
Seems like you covered the bases,  not sure, but I have a smaller hp on the mower, and was told that Kohler changed the specs on an orfice within the carb due to epa stuff, mine still sputters, the other thing although you did change wires and sensor, this seems the only electrical you addressed, could the voltage be breaking down while loaded and or could it be the mechanical governor? It seems it only happens while under a load,
only have a few chain saws I'm not suppose to use, but will at times, one dog Dolly, pretty good dog, just not sure what for yet,  working on getting the gardening back in order, and kinda thinking on maybe a small bbq bizz,  thinking about it,

Offline POSTON WIDEHEAD

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Re: Down in the Dumps with my Kohler Engine
« Reply #5 on: March 02, 2016, 07:30:56 PM »
Air Filter  ?  Maybe

Yes....BRAND NEW Kohler air filter. Inner and outer.

The engine is EFI. No carburetor.
The older I get I wish my body could Re-Gen.

Offline StimW

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Re: Down in the Dumps with my Kohler Engine
« Reply #6 on: March 02, 2016, 07:34:04 PM »
I would check valve clearance and make sure the rockers are lifting high enough.
It would not be the first camshaft with lob worn off.
Also could be ignition breaking down hence the fuel smell. Might try a new coil or two and keep old one for spare if that's not it.
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Offline starmac

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Re: Down in the Dumps with my Kohler Engine
« Reply #7 on: March 02, 2016, 07:51:18 PM »
Odd that the hydraulic backstops will cause it, that would or should be just a small load from the alt. Almost seems like something electrical is going on.
Old LT40HD, old log truck, old MM forklift, and several huskies.

Offline POSTON WIDEHEAD

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Re: Down in the Dumps with my Kohler Engine
« Reply #8 on: March 02, 2016, 07:55:52 PM »
Odd that the hydraulic backstops will cause it, that would or should be just a small load from the alt. Almost seems like something electrical is going on.

This is what we have been talking about since replacing the other parts.  I checked the alt. and battery with the meter everything is fine when the engine is at idle and when the blade is running. However, I cannot check it when I raise the backstops.....not enough hands. I may pull the alt. and take it and get it checked out at the shop so they can load it up.
The older I get I wish my body could Re-Gen.

Offline hamish

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Re: Down in the Dumps with my Kohler Engine
« Reply #9 on: March 02, 2016, 08:00:37 PM »
Is the MIL on? (malfunction indicator light).  If so pull the code and unveil the gremlin causing your problems.


Also check for a vacuum leak usually on the intake, verify your governor settings, and check your throttle position sensor.

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Offline POSTON WIDEHEAD

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Re: Down in the Dumps with my Kohler Engine
« Reply #10 on: March 02, 2016, 08:05:58 PM »
Is the MIL on? (malfunction indicator light).  If so pull the code and unveil the gremlin causing your problems.


Also check for a vacuum leak usually on the intake, verify your governor settings, and check your throttle position sensor.

The code light does not work at all. I told WM about it and they didn't say anything.
I went through turning the key on and off 3 times as the book said....it doesn't work. Its like it never was hooked up.
The older I get I wish my body could Re-Gen.

Offline hamish

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Re: Down in the Dumps with my Kohler Engine
« Reply #11 on: March 02, 2016, 08:15:27 PM »
So most likely the MIL was optional (the engine spec number can confirm this), and why any manufacturer (Woodmizer in this case) would not automatically include it is beyond me. 

Stop chasing your tail (goats have tails too!), pull the motor and have a Kohler dealer pull the codes.

Guessinosis is a terrible way to troubleshoot things.
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Offline Jim_Wahl

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Re: Down in the Dumps with my Kohler Engine
« Reply #12 on: March 02, 2016, 08:20:12 PM »
There was a TSB out about those engines having inadequate grounding a few years ago. Kohler should be able to tell you about it.
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I am from Iowa, but I seem fine.

Offline Ox

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Re: Down in the Dumps with my Kohler Engine
« Reply #13 on: March 02, 2016, 08:21:31 PM »
It's sounding like you have an intermittent engine control problem.  There must be a "brain" somewhere (PCM - power control module), this being an EFI engine.  I'm guessing this is the culprit.  You've covered all the other problem areas.  Your problem is likely in the circuit board of the PCM.  A new one will probably fix your problem.  Whenever I ran into these types of problems on vehicles and there are no codes thrown but still has a slight problem running, a new PCM always solved these annoying little problems.

One question: is this engine built with adjustable valvetrain or is it hydraulic lifters and requires no valve adjustment?  Just curious...for future reference for myself.
K.I.S.S. - Keep It Simple Stupid
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Offline POSTON WIDEHEAD

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Re: Down in the Dumps with my Kohler Engine
« Reply #14 on: March 02, 2016, 08:53:04 PM »


One question: is this engine built with adjustable valvetrain or is it hydraulic lifters and requires no valve adjustment?  Just curious...for future reference for myself.

I truly have no earthly idea.
The older I get I wish my body could Re-Gen.

Offline KirkD

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Re: Down in the Dumps with my Kohler Engine
« Reply #15 on: March 02, 2016, 08:57:02 PM »
Sounds like ignition but don't rule out exhaust. It could have broke something in the muffler that is restricting it. I chased my tail (which I don't have) for a long time once on a muffler that had been plugged by mice filling it with oats for the winter. Hold your hand over the end and feel the pressure difference while you put under a load.
Wood-mizer LT40HD-G24 Year 1989

Offline ncsawyer

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Re: Down in the Dumps with my Kohler Engine
« Reply #16 on: March 02, 2016, 09:01:56 PM »
My guess would be something in the "brain".  Too bad the check engine light doesn't work, that would probably help immensely.

It seems like everything now is has a computer involved.  My old mill had a 18HP Briggs.  Over 2,000 hours and I never did a thing except change the oil and air filter.  I don't think I ever even changed a spark plug.   
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Offline OffGrid973

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Re: Down in the Dumps with my Kohler Engine
« Reply #17 on: March 02, 2016, 09:08:57 PM »
I know you said no carb but I had this issue I couldn't figure out with my snowblower this year and the culprit was related to air intake screw (3:20 into video), not sure if this concept exists on your engine but figured it couldn't hurt to share at the point. 
Your Fellow Woodworker,
- Off Grid

Offline Sixacresand

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Re: Down in the Dumps with my Kohler Engine
« Reply #18 on: March 02, 2016, 09:15:41 PM »
I don't know either, but since you have not mentioned it, maybe the fuel injectors are worn, since they are electo/mechanical devices. If the ports have worn and become enlarged, it might be allowing excess gas to be injected (black smoke) under load.  I have same engine but no where near 1100 hours, so I will be taking notes so when mine starts acting up.

Offline pineywoods

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Re: Down in the Dumps with my Kohler Engine
« Reply #19 on: March 02, 2016, 09:30:47 PM »
Dave, there is an engine control module under a cover on the outboard side of the motor. right behind the non-functional status light. It definitely contains a micro-processor (computer).  Computers don't like spikes and dips in the power supply. If actuating the hydraulics for the backstop causes the problem, what about the loader or toe rollers ? Chances are, there's nothing wrong with your motor, arcing and sparking somewhere else causing voltage fluctuations in the 12 volt  electrical supply causing the control computer to go bonkers.. OH and for what it's worth, the last one of these I wrenched on, the bulb in the status light was burned out...
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