Genny shutting down when getting on plane

beachcombersc

beachcombersc

New Member
May 7, 2007
576
Charleston S.C.
Boat Info
1999 3870
Engines
3116TA
Hey guys,
For some time now I have had my Genny shut down sometime after I throw the hammer down to get on plane. Half tank of gas at least, the genny had been running for hours fine. I think it might have something to do with the demand of fuel or too much voltage(DC type) Anyone else ever hear of similar problems? It can happen while at cruising speeds too. I told my wife to restart it yesterday after we were running for 10 minutes or so, and it still shut down. It seems to do it only when the mains are more than idle...

I have also had some breakers pop from time to time after cruising. Its always the same ones. Blowers/bilge

I have also been concerned with the voltage gauge reading for the port engine. I see it way up near 16v. I have metered it while at the dock and it seems fine then...

I have recently had to replace the manual bilge due to expanding almost like a water bottle would after freezing. maybe due to heat or over voltages...

When I changed out the Idle speed control last month, the two wires and plug ws a bit melted together. Has been fine since I changed it.

Not sure if any of these things are related. I am usually a very good trouble shooter, but this ones going too many directions.



I know the issue with the 5.0s and the booster pump. But didn't know if that could mean me as well...
Stats-
2003 280 w/160hrs
twin 4.3 w/Alphas
5(I think)kw genny (kohler)
 
I would like to see some advice on this one!! As I have had nothing but issues on my Kohler 5-E KW Genny. If I did not have to pull a engine to get mine out, I would throw mine over board and buy a new one as mine only has 200 hours!!!

First, What kind of shutdown are you having?? There is 4 automatic shut downs on that generator?

VOLTAGE, OIL PSI, OIL LEVEL, & WATER TEMP

If it is shutting down due to temp, then I would say you are having a raw water / intake problem. Have you compaired water flow from exhuast while on plane from stopped?

First making sure that strainer is clean and oil is full.

I would check:

Raw water intake (clogged )
~In or out of the water, run a long coat hanger into intake

Strainer gasket (leaking / sucking air)
~Check or replace. You can flip gasket over if smashed thin.

Raw water pump impeller (wore / defective)
~Remove pump cover, check impeller

Heat exhanger cooler (dirty / restricted flow)
~Remove exhanger and check restriction with garden hose
~Shake exhanger. If debris, it will rattle inside
~If o.k, clean with Meratic Acid and reinstall
~Before reinstalling, blow through exhanger to verify no restrictions

If it was fuel filter, it would shutdown at anytime. Change fuel filter. It's cheap and easy to replace, as it's a maintenance item anyways. Cut old filter open and check for debris inside. If you had that much debris in generator, you would have the same amount in engine filter(s).

Generator has a higher pick-up tube than engine(s) do. You would hope it's not a pick-up tube problem. That would mean it never cuts out when tank is 3/4 to FULL. I would be checking this as a last resort.

My voltage on starboard gauge runs higher than my port gauge usually 15 to 16 volts most of the time. I also draw a lot of 12-volt accessories at once for long periods of time too. Note: (my batts are like new) I would say you don't have any problems here but would like to see what others have to say!

Only suggestions are to swap batteries for each engine and see what you got. Also, use a digital voltmeter while diagnosing before and after battery swap. Gauges may not be accurate.

Breakers popping...... Should not have anything to do with generator shutting down. That generator has built in breakers and they would trip if major short or draw. Sounds like you have a bilge / blower pump intermittently failing. You would have to check each pump and blower individually. Bad/Lose connection, Resistance, and / or Amp draw.

Just my 2 cents, hope this gets some ideas flowing to figure your problem out. It can get frustrating!

Just ask me, this is my wife when my genny acts up!! :smt021
 
In all likelyhood, your genny is not able to overcome the venturi effect at the water inlet and is simply not able to get enough water. I am finding that this is a common problem - especially in the 260-280 boat sizes. You are lucky if your genny is shutting down before damaging the impeller - some people are not so lucky.

You can and should try the things suggested above, but I bet you will find that only solution is to avoid running the genny above a certain speed.

Issue was also discussed in this thread: http://www.clubsearay.com/forums/viewtopic.php?t=3475
 
I would have to say that the top three of all those thoughts would be...

1. Fuel starvation.

2. Lack of water.

3. Oil level /sensor

I cant remember having any trouble last year with it, so something has changed...

For a little while I had the port engine just quit during cruising speed. Around the time shortly after the ISC motor was changed.

Sooo many things to check...
 
Hey guys,

I've seen this question/concern come up several times now and if you are really having a problem with water intake using a standard thru hull fitting, why not try a footed/slotted pickup thru hull like the ones used for A/C intakes?

Better yet if you already have one installed for your A/C connect it to your genny teporarily and run it on plane to diagnose if that's your issue. Then you should know for sure. Since you have closed cooling there should be no water ingestion issues.

Just a thought...

Dan
 
A slotted intake could actually force enough water into the generator to overcome the muffler and flood the cylinders. Thats was the generator and AC use different thru hulls
 
What on EARTH is the point of having a generator running when a Sea Ray under 40 feet is under weigh? No one belongs down below when the boat is on plane. We only use our genny when moored or anchored, or when on a 5 knot harbor cruise.
 
Bounty said:
What on EARTH is the point of having a generator running when a Sea Ray under 40 feet is under weigh? No one belongs down below when the boat is on plane. We only use our genny when moored or anchored, or when on a 5 knot harbor cruise.
Click to expand...

We run ours quite frequently while under way to keep the cabin cool when coming back in. We've had 90+ temps here for about 30 days straight.
 
Bounty said:
What on EARTH is the point of having a generator running when a Sea Ray under 40 feet is under weigh? No one belongs down below when the boat is on plane. We only use our genny when moored or anchored, or when on a 5 knot harbor cruise.
Click to expand...

When you have 95 degrees and 100% humidity, you NEED the AC on the entire time your cruising or it will be real hot down there when you get to where you are going...

The big problem here is the water temps are SO high, the AC has a hard time pulling down.

Also, I dont see any problem with ppl down below while cruising. Where we are water is almost always flat. Now if the seas are up, Thats a new story...
 
I admit that that never occurred to me, about the heat being that bad. There is not one day a year that it is like that in Southern California. :huh:

Nevertheless, I am not convinced that most Sea Rays, other than the very large ones, are designed for the generator to be running while the boat is on plane. Too easy for the genny to fail to pull in enough sea water into the cooling system. This can cause the impeller to fail in short order. Hope I am wrong, and good luck. :thumbsup:
 
I will have to come up with a better way to supply water to the genny without flooding it at anytime. I will not accept the "just dont run it while cruising" Thirty minutes while cruising can cool down below quite a bit.
How about a loop system with a foot/strainer supply, and a discharge fairly close with the pick up hose to the genny tapped into the center of the loop. Also having a larger area near the tap as to slow down the flow and remove the affect inside the hose at the T. The whole unit would be below the water line and always stay flooded.
 
Just be very careful as it is way too easy to feed water in faster than the genny can expel it. When this happens, water backs up into the cylinders and it's all bad news from there. The genset installation manuals very adamantly advise against scooped thru-hull pickups for this reason.

You may be able to experiment with slower speeds (but still on plane) and find a point where it still runs ok. Mine does fine if I just get on plane and don't run too fast.

You are not alone in your frustration. I have 2 friends with identical 270s, both with 5Es. One can run as fast as he wants with no problem. The other became quite proficient in replacing impellars until he realized what was eating them. There doesn't seem to be any difference in the way the gennies are installed.
 
Well this one brings my dummy of the year award. As my eyes are weak and its real difficult to get my 300# 5'8" frame down below, I found that my problem was low oil. Took it to dealer and found out I was reading the stick wrong. :smt021 They were so generous to only charge me 1 hour and the pint of oil. They did give me a lesson on how to read the dip stick. :smt038
 
GREAT - But, what a discussion leading up to such a simple solution! The frustration, ect. So, just so we all get something from this, please describe the correct way to read it, and if you don't mind, please let us know what you were doing wrong. I'll bet money that someone will benefit from your input, and it might be me!
 
I will post all my findings as I come to them...

If it ends up being low oil or something simple.. I will still post with shame.

I of all ppl always tell everyone, check the easy stuff first. rule out everything and assume nothing....

Hampton, Do you have a Genny? Have you ever had problems with yours?

Thanks everyone!!!!
 
Hampton said:
GREAT - But, what a discussion leading up to such a simple solution! The frustration, ect. So, just so we all get something from this, please describe the correct way to read it, and if you don't mind, please let us know what you were doing wrong. I'll bet money that someone will benefit from your input, and it might be me!
Click to expand...

I'll check it again when I head out for 5 days and post the info when I get back. Your statement is so true. It was 105 outside and I went into the marina to get a bite to eat and my wife had joined me after working grave yard. I am sitting in side watching the boat waiting on my food when I look down at the boat and notice her opening the hatch. Of course I am think " what is wrong with this women letting my cold air out :smt021 ". After i eat, i go back to the boat and find her setting up on the bed instead of sleeping, red as a beat and of course my usual charm I ask her what the problem is. She says to the ac quit. Well the gens off did you try to start it. Only 10 times. OK now I know I messed up. I think you get the picture. :smt014 :huh: Needless to say getting the boat out to cooler water was must. Oh and crow for dinner.
 
I'm not a 100% certain, but I thought I read in my 5E manual something about a not to exceed degree of running angle while on plane....and if it is exceeded the gen will shut down.
 
I've had some genny issues, but mostly pretty simple. We get a lot of weeds where we over-night. One night, we were sitting on the beach by a fire, and I noticed how lound my genny sounded. At 7am, it shut down after heating up. It sounded loud because of reduced water flow. It shut down when it couldn't take it any more. That was our first night out after getting it home - lesson learned.

I've done an oil change - that was a mess - now I have the right size of drain tube. I've replaced the zinc and the impellar. I've put 300 hours on it in 8 months, and I turn it off unless we are sleeping or using it to cook!!!!!!!!!!!!

So far so good, but I hate to jinx myself (knocking on wood).
 
Well it was oil, or lack of that seemed to be giving me trouble. Once topped off, the thing ran for 7 1/2 hours no problems. Cruising at 46mph for 30 minutes, moved anchor spot due to wind change and tides, the cruised at 35 mph with ski in tow and it never even sputtered...

Thanks for eveyones time and help!!!
 
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