Kohler 5ecd Generator shuts down - EC72

Vince_nj1

Active Member
TECHNICAL Contributor
Aug 25, 2008
1,819
North Barnegat Bay
Boat Info
2006 320 V-Drives 6.2s, Bow Thruster, Generator, Raymarine C80, Radar, Fish Finder
Engines
6.2 Horizons 320HP
Some background:

Boat is a 2006 320. Purchased used in 2008 with 67 hours on the main engines. At the time of purchase the generator was not running. I had a Kohler certified repair tech come and fix the generator last Sept. The main controller board was bad and was replaced under warranty. I don’t know how many hours were on the generator, but I don’t think it had many. At the same time the tech performed a recall service on the exhaust system. The recall was to change something in the exhaust that prevented the catalytic converter from clogging due to salt water crystallizing inside it. The service was completed just prior to winterization last year.

This year I have had very little use of the generator… Maybe 3 or 4 days on the water with the AC running. The mother board reads 26 hours.

3 weeks ago the generator shut off after running for about 2 hours with and EC72 code. When I returned to the marina I reset the switch and noticed the coolant level in the overflow tanks was a little low. I added water/antifreeze and ran the generator and thought everything was fixed. I attempted to use it again 2 weeks ago and it shut down again after about 1 hour. I an getting good water flow checked and the impeller. (I opened the cover and it looks new) I ran the generator and watched the temp rise to 190 and hold that temp. I checked the oil and it is at the right level. Everything seems fine.

I read that a weak battery could cause this error code. I checked the voltage on my 4 batteries and they read right around 13.3 volts. I also checked the water level and they are all full. I don’t have a load tester, so I am limited on what I can do. All 4 batteries are Group 27 starting batteries. They are wired in 2 banks. I forget the difference between series vs. parallel, but the positives and negatives are on the same cable for each bank of batteries. I moved 3 of the batteries around, in the hopes of moving the problem battery to a different bank if I have one.

I ran the generator again after this and it shut down after ½ hour with EC72 code.

So, I am reluctant to call the Kohler tech only to find out that I have a simple issue that is not covered under warranty. I would hate to pay a $500 bill only to find out that I need new batteries. I also don’t want to buy new batteries because I am not conviced that they are the problem and it doesnt make sense to buy them now when the boat is coming out of the water in the next 4 weeks.

Any advice?
 
Just curious which Catalytic Converter they installed on your boat. They have 4 designs now. Mine is the new design that has a fitting on the side of the CC in lieu of the slots. Mine would shut down randomly with a LOC error - but everything would look fine. Generator is suppose to run in the 190's.
 
Just curious which Catalytic Converter they installed on your boat. They have 4 designs now. Mine is the new design that has a fitting on the side of the CC in lieu of the slots.

Not sure what was installed. Maybe you can tell from this pic. I took it after the motherboard was replaced but I'm not sure if the recall service on the exhaust was completed. I don't have the paperwork with me at work, so I can't answer that question until tonight.

P1020806.jpg
 
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It's looks like you have the original exhaust - It is not the most recent exhaust design - but this was a Service Bulletin not a recall - so unless they came out for that issue they probably left it alone or cleaned the ports on the Catalytic Converter. In the new design - the bronze fitting going to anti-siphon valve is removed and capped. You can see it in your pic above the catalytic converter. The hose is run directly to the catalytic converter. The catalytic converter has a cooling port on the side for the water to dump mid way on the catalytic converter.
 
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The picture must have been taken after the motherboard was replaced but before the exhaust work was completed. I will take an updated pic next weekend.

I am suspicious of a wiring connection. Given that they replaced the motherboard and EC72 is CAN Buss error, it could be caused by a loose connection. I think I will have the tech come back and check it out.
 
Just curious which Catalytic Converter they installed on your boat. They have 4 designs now. Mine is the new design that has a fitting on the side of the CC in lieu of the slots. Mine would shut down randomly with a LOC error - but everything would look fine. Generator is suppose to run in the 190's.

Not to hijack - but I'm having the same issues with the LOC error. Coolant level is fine. It doesn't shut down, but often it won't start up unless I do a manual reset. Then it runs fine.
Does yours still have this issue, or were you able to correct it?
Thanks,
Keith
 
The new catalytic converter has been great so far. 10 hours with it and not a issue.
 
Hello All,

Just to let you know I have had the EC72 on a reoccurring basis. Would run then stop suddenly and show EC72. Would clear it and restart after a while would do it again. Kept progressively getting quicker and quicker to the point it wouldn't start, would try to start but then show EC72 right away.

1st fix by Kohler guys was to replace the K5 Main power relay. From the factory it was a cheap made in china no-name 30A relay. Was replaced by Bosch relay. The reason was the relay contacts were getting burnt and carbon build up on it, and wasn't getting power to the ECU on the back of the genny, it also started affecting the fuel pump at the end.

The 2nd time I got the EC72 about 5 months later, it was narrowed down to the 120 Ohm resister on the CAN bus, located closest to the front starboard side of the genny. A new resister was soldered into place and has worked like a champ ever since.

Hope this helps,
Chris

 
Chris

Thanks for the feedback. I will pass this info on to the Kohler Tech.

My next problem is that the unit seems to be loosing cooling fluid each time it runs. I filled the expansion tank, ran it for 1/2 hour and after cooling down, the expansion tank was low again. I filled the tank again (above the high line this time), ran the unit an after cooling, it was back into the normal level.

26 hours on the unit. I am not happy with this POS.
 

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