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Go back to where the generator is installed. You will see there is a grey control cable going into the right side of the generator where all the plumbing lines are. At the very end of the cable you will see there is a red, white, black and maybe a brown strand coming out of the end of the grey cable that goes into a molex connection that plugs into the side of the generator. Keep in mind where you see the red and white strand connected, which should be the two top female ports on the 4 port connection. Unplug the cable and take a metal paperclip or jumper wire and jump across the two top ports, keep the connection in place. This should cause the unit to fill and then produce steam. If it does, this could mean the controller has gone bad, possibly due to moisture damage. You can also remove the controller from the wall and jump the red and white wire that connects to the back of that controller just the same to isolate if the control cable is bad.
It is a design flaw having a check valve orifice built into the steam generator.<br />The plastic sleeve gets hot and get hard and shrinks enough to cause blockage at the inlet to steam generator.<br />Also a lot of sediment builds up inside steam generator from impurities in the water which eventually causes a problem and block at the mop head.<br />solution would be to move the check valve from the steam generator to the pump discharge line where it is cooler. and use only distilled water. they should also use a stainless heater element instead of pot metal as it corrodes.<br />
First verify that the breaker for the outlets is not tripped and make sure that the generator is running at full operating speed. let it run for 5-10 minutes and check for output power. If there is nothing, there are two possible problems. One could be that the automatic voltage regulator is bad. The other is that the field needs to be flashed - a high possibility if the generator has not been run in a long time. There are many videos on the internet that show you how to solve both of these problems. Just do a search for No output from a portable power generator.
-error 5 is caused by the back pressure of the steam head if water supply to the generator is sufficient and the steam output pipe to the steam head is plumbed according to the manual. -Kohler recommends to modify the steam head to remove the wax motor, spring and snap ring in the housing. Call Kohler for instructions.
I would venture a guess that the heating element has become intermittent with a short. Wasn't so bad before, but played heck with controller due to noise from arcing, but now have a dead short when heater reaches temperature.
Occassionally an Autoflush Valve may stick open or partially open. This can happen in hard water areas due to calcium build-up or if debris is caught in the valve. Boiling water will escape to drain and cold make-up water will enter the generator. This results in diminished steam output. Removing the debris should correct his condition. Be sure to follow all precautions as directed in the MrSteam Installation, Operation and Maintenance Manual available from MrSteam or posted online at mrsteam.com. Or call call MrSteam technical Service at 800 767-8326 for assistance.