Still having generator problems

R

Ralph vaughn

Member
Nov 14, 2018
259
Atlanta Ga
Boat Info
2007 Sea Ray 290 radar & GPS, triple axle trailer. 2006 Sea Ray 280 radar & GPS & triple axle tlr
Engines
5.0 MPI closed cooling Sea Core engines & Bravo III outdrives
4.3 MPI with alpha outdrives
My 2008 Sea Ray 290 5ECD generator still will not run. I’m on several waiting lists to get someone to look at the problem.

today I purged the fuel line using the built in Schrader valve. The generator started and ran 20 minutes and shut itself off. Didn’t sound like fuel starvation. It then threw a code “1000 err” but only on the salon LED. I also could not reset the err code using the engine bay LED panel and the stop/reset red rocker arm switch.

anyone know what the 1000 err code is. I don’t see it on the list of error codes in the Kohler manual. Also anyone know how to reset the code.

thanks.

Ralph
 
I spent a lot of time trying to troubleshoot what sounds to be a similar problem on my 7.3 ECD. It would run for a while and then shut down with an ambiguous error code. There is much information on various forums and plenty of advice. The time I spent troubleshooting was a good learning experience However I didn't get it resolved until I hired a certified Kolher mechanic. He placed a pressure gauge on the Schrader valve and observed a drop in pressure indicating a bad high pressure fuel pump. He replaced the pump and the injector and it’s running fine now.

The thing that I missed as I was troubleshooting was that the fuel pressure was fine when it first started but as the fuel pump heated up the pressure dropped and the generator stopped running and would not start until it cooled down.

I don’t know what your code indicates. The codes reset whenever you turn battery power off to the generator.
 
Those stupid Kohlers are such a PIA. I was constantly troubleshooting mine when i had a 360. If it wasn't fuel related, it was cooling, or plugs, or carb/choke/linkage, or bad sensors, or corroded wires. I had your issue twice. Both the same scenario where it would run for 20 minutes than shut down. Once it was a fuel pump, and the other time it was air bubbles in the coolant. For the coolant, open the bleed valve, and get a threaded nipple from the hardware store to screw in there. Then get a pump and a little bit of suction on it. Don't let the coolant level get low. You shouldn't need to pull much fluid at all. Then proceed to squeeze every coolant hose on the genny with hopes that more bubbles surface through the bleed valve. Shut the valve quickly, top off coolant, and hopefully you are good to go.
I had the year before the ECD version came out. Same genny less the more "advanced" electronics which create their own issues. As you can tell i'm not a big fan of that genny. My best advice is once working, run it often under load and it should continue to work, until it doesn't..... Good luck.
 
Just put in an order for some maintenance parts to my Kohler guy and asked about your code 1000.
His response was that code 1000 is not a Kohler code but rather a fault code specific to your salon controller. (Smartcraft??)
He's said for you to try and disconnect the salon canbus connector at the 5ecd itself. Then try and run gen set generator without salon connector installed. Hard codes on Kohler 5ecd will be stored if any.
Call Darryl at 941-224-6616. He sold us our 5ecd and it works flawlessly. He's the best I've run across.
 
I'm going to keep track of this thread.

I have a 4kW and I swear you can set your watch for 20 minutes and it will shut down.

I only use the generator for the occasional pot of coffee or a bag of popcorn so it runs long enough for that.

So far last year I cleaned out the heat exchanger and changed out the coolant. Replaced the temp sensors on the manifold because I found one had cracked and the wire was barely hanging on and it still shuts down.

Additionally I'm going to change my oil to a straight 30 weight some time this year and see if that changes anything. I also have an oil pressure sensor and a coolant temp sensor to change just to rule them out. But I never considered the fuel pump.

BTW an easy way to bleed the air out of your coolant system is to just leave the cap off and let it run. At least on the 4kW you will see coolant flow and also be able to add some coolant when it takes a big gulp when the thermostat opens up.
 
I have been battling generator issues pretty much since I bought my boat a few years ago. Kohler 5e.
I finally removed it, and took it to a tech for diagnosis and repair. We had to replace the Choke assembly, raw water pump and the circuit breaker. Fuel pump was replaced prior to removal in an attempt to get it started. He has it running on his bench under load and we think that we will be good to go when reinstalled on the boat. But you are right, they are a major PIA.
 
Thanks guys for your input. Much appreciated

ralph
 
PeteL said:
I have been battling generator issues pretty much since I bought my boat a few years ago. Kohler 5e.
I finally removed it, and took it to a tech for diagnosis and repair. We had to replace the Choke assembly, raw water pump and the circuit breaker. Fuel pump was replaced prior to removal in an attempt to get it started. He has it running on his bench under load and we think that we will be good to go when reinstalled on the boat. But you are right, they are a major PIA.
Click to expand...
How hard was it to remove the generator from your boat. Did you do it yourself or pay someone

ralph
 
Ralph vaughn said:
My 2008 Sea Ray 290 5ECD generator still will not run. I’m on several waiting lists to get someone to look at the problem.

today I purged the fuel line using the built in Schrader valve. The generator started and ran 20 minutes and shut itself off. Didn’t sound like fuel starvation. It then threw a code “1000 err” but only on the salon LED. I also could not reset the err code using the engine bay LED panel and the stop/reset red rocker arm switch.

anyone know what the 1000 err code is. I don’t see it on the list of error codes in the Kohler manual. Also anyone know how to reset the code.

thanks.

Ralph
Click to expand...

Verify your CO detectors have closed the relay that is wired to them. If the detectors are original, they have reached end of life and must be replaced. The replacements are different but can be adapted. Detector behavior beyond the 5 year life is undefined and erratic.

Also, the button breaker labeled CO on the breaker panel in the cabin can also result in this error code. Ensure it is depressed.
 
Ralph vaughn said:
How hard was it to remove the generator from your boat. Did you do it yourself or pay someone

ralph
Click to expand...
I had my marina remove it. They had to take some of the accessories off the front of the engines to get clearance to get the generator out of the engine bay. 4 hours labor.
 
thanks for the information.'

ralph
 
Generator weight is approximately 200lbs. For our 90 cruiser removal was fairly easy.
1) Fuel Line
2) Exhaust hose - Cut to remove. Don't try to save hoses. West Marine stocks locally
3) Battery cable and can bus wiring to cabin. (Easy)
4) Water inlet hose - Cut and replace with new to sea cock. This is a must. Don't try and save old
5) Winch or hoist. - I had marina pull for me for $210. I had everything disconnected so labor was 1.5 hours
 
Thanks for the post

ralph
 
We had a Kohler on our Regal years back and our starting issues were solved by adjusting the black cap thing on the motor( i believe it was choke related ).The mechanic turned it maybe 1/8 of an inch and the running issues were solved.
 
You must log in or register to reply here.

Forum statistics

Threads
113,177
Messages
1,427,986
Members
61,086
Latest member
MrWebster
Back
Top