Kohler 5ECD Service Manual page 19

Troubleshooting Chart, continued
Problem Possible Cause
Cranks but
No fuel
does not d
Spark plugs or spark plug
start
connections
Loose connection or open circuit
Backfire flame arrestor clogged
Incorrect controller configuration
Ignition system spark control or
ignition coil
No engine rotation sensed (check
for an overcrank fault shutdown)
Blown F2 fuse
Blown F4 fuse
Blown F5 fuse
Starts hard Low battery voltage
Backfire flame arrestor clogged
Spark plug(s)
Spark plug wire(s)
Ignition components (spark
control or ignition module)
Worn piston rings, valves
Blown F5 fuse
Blown F6 fuse
Starts but Fault shutdown
shuts
down
Stops Fault shutdown
suddenly
No fuel
Fuel line restriction
Backfire flame clogged
Blown controller fuse (F2)
Blown auxiliary winding fuse (F1) Replace fuse. If fuse blows again, test generator
Blown relay interface board (RIB)
fuse (F2)
Spark plug(s)
Engine overheated (hot engine
only)
Low oil pressure (LOP) switch
Engine overloaded
Loss of generator output voltage
to controller
Ignition module
K3 (flash) relay
TP-6391 9/08
Corrective Action
Check the fuel supply.
Check spark plug wires and connections. Replace or
clean and regap spark plugs.
Check for loose or open connections at the fuel solenoid
and at the engine control module. Check
controller/engine wiring continuity.
Clean or replace.
Check for correct controller configuration parameters:
unit configuration (UC) and engine configuration (EC).
Test and/or replace components.
Check for locked rotor.
Replace fuse.
Check GNDs on coil.
Check ECM ground connection pin 14.
Check battery voltage.
Clean or replace.
Replace or regap spark plug(s).
Check spark plug wires and connections. Replace
spark plug wires.
Test/replace ignition components.
Check compression.
Check ECM ground connection pin 14.
Check voltage regulator wiring.
Check for a fault shutdown code on the controller's LED
display. Correct the fault and then move the generator
set master switch to OFF/RESET to reset the controller.
Check for a fault shutdown code on the controller's LED
display. Correct the fault and then move the generator
set master switch to OFF/RESET to reset the controller.
Check the fuel supply.
Inspect fuel lines.
Replace element.
Replace fuse.
components.
Replace fuse.
Replace and regap plug(s).
Check air intake, fuel, oil level, air inlet/outlet.
Attempt startup. If unit shuts down, remove lead from
LOP switch and reset controller. A successful restart
attempt indicates a faulty LOP shutdown switch.
Note: Check engine oil pressure before performing test
and/or replacing LOP shutdown switch.
Reduce electrical load.
Check connections at P15 plug.
Check continuity of AC sensing leads 11 and 44.
Test and/or replace.
Check for Flash LED illumination. Check RIB fuse.
Replace relay board.
Reference
—
O/M
Section 7
O/M
Section 4.11
Engine S/M
Section 5.4
Section 5.12
Section 7
Section 7
Section 7
O/M
O/M
O/M
Engine S/M
Engine S/M
Engine S/M
Section 7
Section 7
Section 4.5
Section 5.10
Section 4.5
Section 5.10
—
—
O/M
Section 5.12
Section 5.12
Section 5.12
Engine S/M
O/M and I/M
Engine S/M
I/M
Section 7
Engine S/M
Section 4.6
Section 3 Troubleshooting 19