KOHLER GENERATOR

[Peter Holland]

Hi there. I have a 2012 Sea Ray 370 Sundancer with a 4 k Kohler petrol generator. The generator wont run and I've had 2 marine electricans try and repair it but with no luck. The fault codes are numerous so they havent been able to tell me what is wrong but they have now given up on trying to fix it. They have suggested I have it removed at sent to Kohler in Brisbane (Aust) which is about 1600 klm from where my boat is berthed. Sounds horrendously expensive.
It may be that I can replace it at a cheaper cost although I dont believe Kohler make petrol generators anymore. Can anyone please suggest what I can do as I'm at my wits end having had this issue for 6 months.

 

[Ididntdoit]

an electician because it wont run???? check the combo fuel cooler, pump module - lots of problems with it.....

 

[DennisWittig]

Aren’t those new ones (mines an 04 so I call 2012 new) relying on a Carbon monoxide sensor ? Just Something to consider. Wondering what doesn’t run means. Does it turn over, start at all, run rough, stall or what. Lots of people might offer ideas, check for gas, check for spark, then all the safety stuff like the carbon monoxide that I think could shut it down if not good sensor

 

[Peter Holland]

Hi there. I have a 2012 Sea Ray 370 Sundancer with a 4 k Kohler petrol generator. The generator wont run and I've had 2 marine electricans try and repair it but with no luck. The fault codes are numerous so they havent been able to tell me what is wrong but they have now given up on trying to fix it. They have suggested I have it removed at sent to Kohler in Brisbane (Aust) which is about 1600 klm from where my boat is berthed. Sounds horrendously expensive.
It may be that I can replace it at a cheaper cost although I dont believe Kohler make petrol generators anymore. Can anyone please suggest what I can do as I'm at my wits end having had this issue for 6 months.

Aren’t those new ones (mines an 04 so I call 2012 new) relying on a Carbon monoxide sensor ? Just Something to consider. Wondering what doesn’t run means. Does it turn over, start at all, run rough, stall or what. Lots of people might offer ideas, check for gas, check for spark, then all the safety stuff like the carbon monoxide that I think could shut it down if not good sensor

Thanks Dennis
Initially the generator wouldn't start, and now it starts but it overloads within 30 seconds of running. The electrician said it also showed several other fault codes (but I dont have those on hand.)
I'll certainly try the carbon monoxide sensor theory but I've almost resigned to replacing the whole thing as its cost me about $2,000 already. But if I was to replace it, what do you replace it with as I dont believe Kohler make petrol ones anymore.

 

[StefanFL]

So petrol engine part of generator is working? and generator part is having issue?
I would try to disengage gen part if possible or at least make sure there is no load at all, and test that engine is running fine without load.

Once you rule out gasoline part, I would check condition of coils on gen side.

I'm not familiar with electronic on your gen, I have old version from '90s, but if everything above looks good, your might have some kind of control module that's getting false overload trigger.

 

[CaptRonn]

You can throw a lot of money at these old generators, and you'll end up with an old repaired generator.

There are some people selling repaired generators, at hefty prices. Again, how long will it last?

I recently experienced the same thing after spending a $1000 on repairing my gas Westerbeke (new hoses, belts, exhaust manifold, etc) only to have the back end (stator, armature) burn out after 5 hours of use. The repair estimate on that? $3000+. I removed the stator, but due to Westerbeke using cast aluminum on the armature pressed on a steel shaft, I couldn't remove it from the engine.

Finding new gas generators is getting tough. Westerbeke still makes one, but very pricey. So I decided to go with a Phasor https://www.phasormarine.com/k3-7-0pmg.htm . It's a diesel genset, so I installed a 23 gallon plastic diesel fuel tank to supply it. At .5 gallon/hour, this gives me plenty of generator time.

The main advantage is no more worries about exhaust fumes with the genset running. And the Westerbeke turned at 3600 rpm while the Phasor turns 1800 rpm, so much quieter.

All in all I feel I made the better choice, I now have a new very reliable genset.

 

[Stray Current]

List the model number and fault codes. I may be able to help, and there is a lengthy thread here on all manners of Kohler issues as well.

http://clubsearay.com/index.php?threads/kohler-5ecd-not-running-ec62-uu-uf.92126/

 

[JimT]

What brand of generator is Sea Ray putting in new gas sport cruisers?

 

[Cocktail Time]

What brand of generator is Sea Ray putting in new gas sport cruisers?

With Kohler and Onan out, that leaves Westerbeke as far as I know. I just texted a friend at a Sea Ray dealer to ask. This is interesting.

 

[stephenm27]

With Kohler and Onan out, that leaves Westerbeke as far as I know. I just texted a friend at a Sea Ray dealer to ask. This is interesting.

I just noticed that Kohler no longer lists any gasoline marine generators on their website...? Did I miss some announcement where they exited?

They only list diesel marine generators now, starting at 4KW.

 

[CaptRonn]

Gas generators are on the way out.

 

[stephenm27]

Gas generators are on the way out.

I love diesel as much as anyone, but they will also have their own set of challenges, especially once the EPA steps in (if they haven't already) to control NOx and other emissions/soot.

There must be some background to Kohler exiting...

 

[Motoguy2158]

Thanks Dennis
Initially the generator wouldn't start, and now it starts but it overloads within 30 seconds of running. The electrician said it also showed several other fault codes (but I dont have those on hand.)
I'll certainly try the carbon monoxide sensor theory but I've almost resigned to replacing the whole thing as its cost me about $2,000 already. But if I was to replace it, what do you replace it with as I dont believe Kohler make petrol ones anymore.

Does it overload or go into overspeed. The generator should be started with no load then let it stabilize / warm up and switch loads. Mine Westerbeke 5.5kw would trip out on overspeed. After having the local guy look at it and telling me it needed a new $400 governor control i called BS. I downloaded the trouble shooting manual and found that my throttle linkage was bent...probably from me cleaning the bilge. I straighten the linkage, lubricated it and it runs great. Un fortunately Westerbeke Tech support isn't much help. They have great manuals on line that might help you run down your issue. Ive been old by many to never start it under load.

 

[firecadet613]

Does it overload or go into overspeed. The generator should be started with no load then let it stabilize / warm up and switch loads. Mine Westerbeke 5.5kw would trip out on overspeed. After having the local guy look at it and telling me it needed a new $400 governor control i called BS. I downloaded the trouble shooting manual and found that my throttle linkage was bent...probably from me cleaning the bilge. I straighten the linkage, lubricated it and it runs great. Un fortunately Westerbeke Tech support isn't much help. They have great manuals on line that might help you run down your issue. Ive been old by many to never start it under load.

I've followed the same practice with my Kohler 5Es and 5ECD. 5 minute warm up and a 5 minute cool down period with no load on it.

 

[CaptRonn]

I love diesel as much as anyone, but they will also have their own set of challenges, especially once the EPA steps in (if they haven't already) to control NOx and other emissions/soot.

There must be some background to Kohler exiting...

 

[stephenm27]

Out of curiosity, does it have a particulate filter on the exhaust? I would assume the EPA will eventually require it, if it’s not already. As soon as that requirement happens, an exhaust regeneration process is needed to cook off the accumulated soot. That process, in trucks at least, generates temperatures of approx 1000 F—-a scary thought in a boat.

I’ll reiterate: I love diesel. I’m just wondering how long it’ll be before the marine diesel industry catches the attention of the EPA and they apply the same expensive/complex emissions restrictions that have been placed on auto/truck manufacturers.

 

[CaptRonn]

Out of curiosity, does it have a particulate filter on the exhaust? I would assume the EPA will eventually require it, if it’s not already. As soon as that requirement happens, an exhaust regeneration process is needed to cook off the accumulated soot. That process, in trucks at least, generates temperatures of approx 1000 F—-a scary thought in a boat.

I’ll reiterate: I love diesel. I’m just wondering how long it’ll be before the marine diesel industry catches the attention of the EPA and they apply the same expensive/complex emissions restrictions that have been placed on auto/truck manufacturers.

You’ll have to ask the manufacturers. I wouldn’t think anything that did come down would be retroactive.

IMO the gas generator market has been shrinking. My only choice was to buy a Westerbeke gas set (at a ridiculous price) or buy the diesel set that sells for less and is far more reliable.

I’m sure there will be a market for used gas gensets. Broward Marine still supports them (back end) and there are engine parts.

FWIW, I found a used Westerbeke gas set, and the seller assured me it was a “fresh overhaul”. He wanted the same money I paid for my Phasor. And I suspect his overhaul was done with a couple of cans of Krylon.

 

[stephenm27]

You’ll have to ask the manufacturers. I wouldn’t think anything that did come down would be retroactive.

IMO the gas generator market has been shrinking. My only choice was to buy a Westerbeke gas set (at a ridiculous price) or buy the diesel set that sells for less and is far more reliable.

I’m sure there will be a market for used gas gensets. Broward Marine still supports them (back end) and there are engine parts.

FWIW, I found a used Westerbeke gas set, and the seller assured me it was a “fresh overhaul”. He wanted the same money I paid for my Phasor. And I suspect his overhaul was done with a couple of cans of Krylon.

I never had any real issues with my 2009 Kohler 5 but would generally agree the data shows they can be finicky. I wouldn’t be comfortable buying a new gas generator at this point, either. Obsolescence is guaranteed it appears.

Similarly, I’ve found that many of the new outboard-powered cruisers (non Searay) are utilizing diesel Fischer Panda generators. It makes it a dual fuel boat, but to me, it’s a positive. Ideally, my next boat will be entirely diesel but that’s a difficult find in the smaller cruiser market right now.