Generator Won't Start

wyrman

wyrman

Well-Known Member
Jul 12, 2012
1,924
Tri-Cities, Wa
Boat Info
2007 310 Sundancer
Engines
Twin 350's, V drives
2003 Fisher 17 aluminum
90hp Honda 4 stroke
I have an 07 Kohler 5c generator. I started it up a few weeks ago for a few minutes and it ran fine. I went to fire it up Friday and the battery wasn't strong enough to turn it over.
I replaced all four batteries and now it turns over great, but it won't start. The only code it gives is OC, or over crank, meaning it has tried too many times I believe.
Is there something that may have happened when the battery went bad that needs reset, or????
I've tried remotely, and at the generator.
What a piece of crap generator it seems.
 
Have you checked the fuses on the front? I had the 5ECD in my 260DA lost the coupler one time between the drive and the impeller. Otherwise, it always started.

Do you have the owners and parts manuals? If not, I can email them to you.

Bennett
 
I did check the fuses. I have the manual at work, will print it tomorrow.
I don't have a parts manual though.
My email is wyrman63@yahoo.com. Thank you.
 
My expertise is largely on Quicksilvers and Westerbekes. That said I did find a manual for the 2006 5ECD to take a look at. I agree with the OP that they have added another layer of insanity to mix. Basically, the OC codes tells you nothing. It simple means that three programmed failed starts have occurred. I can appreciate why they engineered it this way. The raw water cooling system needs exhaust pressure to keep the water from backing up in the engine. By locking out after 3 starts (cranking time is controlled).....they minimize the chances this will occur which based on history has been an Achilles heel for their product.

So to find out what is really going on you need to follow the Reset procedure listed below. Frankly....I have read this section 3 times and it still doesn't make sense when you look at the last sentence.

Anyway, I would reset it and put a spark tester on a plug wire and see if you have spark when it cranks. If you do, then pull a plug and take a look at it's condition. Both Kohlers and Westebekes are sensitive to older plugs and the way you know they need to be replaced is longer crank times. You could have just fouled the plugs from the weak battery and they haven't recovered.


2.6.6 Resetting the Controller after a Fault Shutdown Always identify and correct the cause of a fault shutdown before resetting the controller. Use the following procedure to reset the generator set controller after a fault shutdown.

1. Move the generator set master switch to the OFF/RESET position.
2. Disconnect the generator set from the load using the line circuit breaker. See the safety precautions at the beginning of this manual before proceeding.
3. Identify and correct the cause of the fault shutdown. See the safety precautions at the beginning of this manual before proceeding. Refer to Section 4, Troubleshooting.
4. Start the generator set by moving the generator set master switch to RUN. Test operate the generator set to verify that the cause of the shutdown has been corrected.
5. Shut the generator off by moving the generator set master switch to the OFF/RESET position.
6. Reconnect the generator set to the load using the line circuit breaker.
7. Move the generator set master switch to the AUTO position for startup by remote transfer switch, remote start/stop switch, or remote digital gauge.

Opening and closing the remote start/stop contact also resets the controller.
 
In older Kohler generators, before they put trouble codes on everything, Small Kohlers were known for fouling plugs with a failded start. Once you foulded a plug, the little devil wouldn't start for love or money. Worse, continuing to try to start one with foulded plugs would cause water in the exhaust to fill the cylinder thru the exhaust valve.

Ttherefore, be sure you follow 2.6.6 in the post above before resetting the controller.
 
Great info guys! Thanks a lot.
I think I'll go ahead and get some new plugs, even though they were just replaced when I bought it last fall.
It's going to be Memorial weekend before I will be able to get back down to look at itit unfortunately.
 
As was mentioned earlier - have your checked your raw water impeller or do you know when it was last changed? We just had our generator go out on us last weekend and when we removed our impeller it was completely shredded, no fins left. It had been two years but not that many hours on it so I thought we'd be okay. This is now going on my annual maintenance list.
 
I replaced the impeller in early December of 2017.
 
I don't have any problem changing it again, its easy, and cheap.
I did I start the ngenerator a few weeks ago and it was flowing just fine though.
I'll order another one, along with some new plugs. ( that were just replaced last fall)
 
Could it be a dead fuel pump? When mine died I had similar symptoms minus the OC code.
 
I've been watching this thread and when our Kohler acted up it was the black cap on the top that had to be turned just an inkling ( maybe an eighth of a inch ).
I had an old salt of a friend come down and he figured it out right a way.

Good luck
 
Black cap on top? Hmmm, sure would be nice if it turns out to be that easy. Now I'm wondering what that is.
Unfortunately, or fortunately, we're headed out for a 12 day vacation tomorrow so it'll be Memorial weekend before I can get to it.
 
Choke failure is common. Manually close it and try. The electric actuated spring is under that "black cap", when it burns out it fails. The spring closes the choke on cold start. When it starts the engine vacuum hose that is attached will open the choke a small amount. When the electric actuated spring heats up it will open the choke fully. All 3 functions have adjustments.
 
The way it was acting, my first thought was the choke, but I didn't have the time to dig into it.
 
Had a similar issue on my Kohler years ago and it turned out to be a badly gummed-up carb. Gumout sprayed into the various ports of the carb and fuel line input solved it.
 
Thanks Mike and endless seas. We're going to Bora Bora and Tahaa. Should be great.
 
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