[RE-wrenches] Kohler 8.5RES ignition glitch

Sun Nov 29 12:07:19 PST 2009

I did have the valve covers off and cranked it over a few times, as that was an easy check, all good there, valves, springs, rockers, push rods all functioning fine, this motor is really clean w/ only 262 hours, and about 40 hours on the last oil change. I manually pushed on each valve to check spring tension too.

When I had the visible plug wire off, on the service side of the motor, the engine actually ran pretty good. Then I unplugged the back side and tried running it on the front side plug, it did sputter, but not run good. Then with both plug wires installed it flat won’t sputter or run. This is a strange test to do, I accidentally left the one side unplugged, and when it started and ran good I thought the fresh spark plugs fixed the issue, cracked plug or?

Is it ok for me to call Carl directly today?

Sincerely,

Chris Worcester

Solar Wind Works
NABCEP Certified PV Installer
Phone: 530-582-4503
Fax: 530-582-4603
www.solarwindworks.com <http://www.solarwindworks.com/> 
chris at solarwindworks.com
"Proven Energy Solutions"

From: re-wrenches-bounces at lists.re-wrenches.org [mailto:re-wrenches-bounces at lists.re-wrenches.org] On Behalf Of dan at foxfire-energy.com
Sent: Sunday, November 29, 2009 11:25 AM
To: RE-wrenches
Subject: Re: [RE-wrenches] Kohler 8.5RES ignition glitch

I beleive it's in the wireing compartment just above the AC connections. I think it's a potted module with a few pots showing (to adjust output) and the connectors. Maybe a status LED depending on vintage.

Just got off the phone with Carl. (802-259-2775). He's telling me that there are two coil modules that run off the flywheel on that unit. one for each cylinder. (Besides the  AC control module in the Wiring compartment). He also tells me he doesn't think that's your problem, because you have spark on both cylinders and fuel, and he's never had to replace one of the modules. He suggest it's more likely a stuck valve. (Wrong oil? -- should be synthetic). or a keeper came off. easy enough to check -- just pull the valve covers off and see if the valve stems actually move and are intact. let us know what you find? db

Dan Brown
President
Foxfire Energy Corp.
Renewable Energy Systems
(802)-483-2564
www.Foxfire-Energy.com
NABCEP #092907-44

-------- Original Message --------
Subject: Re: [RE-wrenches] Kohler 8.5RES ignition glitch
From: "Chris Worcester" <chris at solarwindworks.com>
Date: Sun, November 29, 2009 1:49 pm
To: "'RE-wrenches'" <re-wrenches at lists.re-wrenches.org>

Do you know where the ignition control module is located?

Sincerely,

Chris Worcester

Solar Wind Works
NABCEP Certified PV Installer
Phone: 530-582-4503
Fax: 530-582-4603
www.solarwindworks.com <http://www.solarwindworks.com/> 
chris at solarwindworks.com
"Proven Energy Solutions"

From: re-wrenches-bounces at lists.re-wrenches.org [mailto:re-wrenches-bounces at lists.re-wrenches.org] On Behalf Of dan at foxfire-energy.com
Sent: Sunday, November 29, 2009 10:28 AM
To: RE-wrenches
Subject: Re: [RE-wrenches] Kohler 8.5RES ignition glitch

Sure sounds like a faulty ignition control issue. might be a poor connection either at the module or at the crank angle sensor. I do have a call in to me Kohler dude on your behalf. (I generally like to set up a xfer / Alt. AC input source -- usually in conjunction with a j box out at the genny -- especially for me off grid folks. then when their genny goes south, they can wheel up most any POC and get running again.) (John's idea) db

Dan Brown
President
Foxfire Energy Corp.
Renewable Energy Systems
(802)-483-2564
www.Foxfire-Energy.com
NABCEP #092907-44

-------- Original Message --------
Subject: [RE-wrenches] Kohler 8.5RES ignition glitch
From: "Chris Worcester" <chris at solarwindworks.com>
Date: Sun, November 29, 2009 11:47 am
To: "'RE-wrenches'" <re-wrenches at lists.re-wrenches.org>

Hi Wrenches,

Hope you’re all having a great Thanksgiving weekend! I have a disabled off grid client with a vintage Sept. 2006 PV/Gen Hybrid system we installed. The Kohler 8.5RES LPG has 262 hours on it. She called us letting me know they had a power failure. After trouble shooting the system in a snow storm, I’ve deduced the Kohler’s timing is not correct. We have spark on both cylinders & put in fresh plugs just in case, 11” water column on the propane, & it actually runs on one cylinder at a time. When both spark plug wires are plugged in it won’t run. The battery is good.

Kohler was closed Friday, we tried WA, CA, OR, WI, & CO for tech support. Does anyone have a service manual for this unit? I believe it’s the ignition control or possibly another part of the ignition that has failed.

Any help or advice here will be greatly appreciated as always! Thanks in advance.

Sincerely,

Chris Worcester

Solar Wind Works
NABCEP Certified PV Installer
Phone: 530-582-4503
Fax: 530-582-4603
www.solarwindworks.com <http://www.solarwindworks.com/> 
chris at solarwindworks.com
"Proven Energy Solutions"

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