Kohler 5.0 e generator problems

[sbmcwilliam]

Here we go again: it appears my generator needs a new electric controller. When attempting to start the codes go from CC to OC without any cranking. Generator service expert diagnosed what he believes to be the very expensive electronic controller has gone bad but possible electric harness issue if not. Has anyone replaced this controller and/or have an idea where to obtain at a reasonable price? Also, it appears the generator is constantly subjected to water intrusion thus causing damage. Has anyone utilized any type of cover to best protect the generator from the water exposure? Many thanks.

 

[PlayDate]

Welcome.

Is this your first post on the Generator? You stated a few issues so I will attempt to break them down.

1) I believe your generator is a 5ecd since it has error codes. The 5e is a carb unit without electronic controls.

2) Now to the issue. If it jumps from CC to OC without cranking the circuit board that triggers OC is apparently stuck closed. If the circuit board sees 3 crank attempts and throws the OC code and should release the circuit after 5 minutes or so that you can try again. You can force it to release buy switching off the generator battery switch for a few minutes.
That should reset the board and allow you to start the generator. If nothing changes....it could be one of the relays (cheap) or the ADC2100 controller ($1,000). Hopefully it is one of the relays either the K5 Power Relay or the Starter Control Solenoid.

3) I'm not sure what you mean by water intrusion. Usually that term is used to describe water backing up in the generator's engine from overcranking/hard starting. Your generator is protected from that to a large degree by the electronic controller that only allows three attempts before it locks out starting for a few minutes. A hard starting 5ecd usually needs a new set of spark plugs.

4) If you are worried about the generator getting wet......I'm not sure how that would be happening but I believe Kohler does make sound shields for the generator that would cover it.

 

[Sublimetime]

water exposure?? If this is what you mean, water being splashed or pouring down on top of, first I would try to find out where the water is coming from and stop it there. If you cant stop it there you can make a cheap splash shield from a large plastic storage bin bottom. Get a suitable size storage bin and cut off at the bottom to make a tray, turn upside down, and held from above or beside but not in contact with the genny.

 

[sbmcwilliam]

Thanks for the replied. I found an excellent generator mechanic that identified that my regular mechanic replaced the starter selinoid with the wrong model. They look the same but he knew it based on the electrical testing then closer examination. $45 part....after we all were thinking to consider a rebuild. Also, he suggested using a clear office chair floor protector with the spikes on the pad. He says those spikes are enough to keep it off the generator sufficiently to prevent fire/melting and all for air flow.