290 SeaRay Sundancer - Kohler 5K Generator

[CSMady]

I have ~ 400 hours on my Kohler generator. I am experiencing (2) problems when trying to start up the generator. First, I have to bleed some fuel to get the generator to run which is a pain because of where the valve stem is located. I am not sure, but I believe air may be getting in the system. Secondly, once the generator is running smooth I have no problem with using the stove, microwave, hot water heater, etc, but as soon as I turn the A/C unit on the system bogs down and stops. I have to go through the whole process of bleeding fuel off at the top of the generator. The generator runs fine, until I turn the A/C unit on. Has anyone experienced this problem, if so can you give me the details on how to corrrect this ongoing issue.

CSMady

 

[estoltz]

Is it throwing any error codes?

 

[CSMady]

I was getting EC69 - O2 Switching Fault. I looked in the operation manual, but did not have anything listed on how to trouble shoot this fault code. I had the mechanic come over from the local Searay dealership come and take a look at it and he showed me how to bleed the air out of the fuel to reset the 2100 Advanced Digital Control system. The generator ran fine while he was there. Needless to say, that cost was $225 for a service call and the time he was there. I did not think about turning on all the panel switches to put a load on the generator, while the mechanic was there. I called the dealership back and they suggested I bring the boat in for them to trouble shoot the problem. I am hoping to try to figure this one out without sending it to them, for I am sure it will be several hundred dollars and it may just be something simple that I do not know about.

Like, I have mentioned that I have isolated it down to the system only shutsdown now when the A/C switch is turned on at the master control panel, but then on the other hand I should not have to keep bleeding the fuel line everytime to get the generator to run.

 

[estoltz]

http://clubsearay.com/showthread.php?t=72924

Check out this thread. I didn't have an issue with bleeding the line and my generator would shut down even without a load. They ended up replacing a CO board behind the 2100 panel. They said it goes out regularly. I'll try and get the part number and more details. They said it's normally a 215 dollar part but it was under my extended warranty so only cost me 25 bucks.

 

[my DOG HOUSE]

http://www.partsfortechs.com/asapcart/page.html?chapter=0&id=25

The best prices for parts I have found.

 

[estoltz]

Good link. I'm going to have to remember that one.

 

[CSMady]

Do you know if there is a way to verify whether or not that the CO panel is bad? I do not mine spending the $215, but if I change this part out and I still have the same problem than I am back at square one scratching my head.

Thank you for the information, for this is another thing to investigate and rule out.

 

[CSMady]

I found this part number using the link referenced. Board 12V w/CO Sensor (GM46362) for $142. Would this be the correct one? I would have to find a way to test/verify that it is bad before purchasing.

 

[Bay B's]

Hi, interesting you have to bleed fuel off the top. I made a tool for just that purpose I can share details if you like. Have you tried the prime mode before starting? I use the prime mode when bleeding fuel after I change the injector. On another note, did everyone get the recall notice on the Kohler generators?

 

[pepper]

I got the recall notice. Also got one last year and got it done when I did my yearly genset service. This new notice sounds somewhat like the one last year ?

 

[Bay B's]

Don't want to hijack this post Not sure what last year's was. Here is what I just received:
Sea Ray Owner,

Sea Ray® has become aware of an issue that could pose the risk of a fire hazard on boats equipped with a generator.

In two recent field events of a generator experiencing shut down during use, the consumers did not heed the specific fault code information indicating COOLANT LOSS (no seawater flow), cleared the fault code and restarted before resolving the underlying issue. Successive restarts with COOLANT LOSS (no seawater flow) builds heat in the exhaust hose and may eventually lead to a fire.

The KOHLER generator remote gauge, on generator visual display, and the generator owner’s manual provide key information when a fault occurs. The no water flow fault is shown as 62 ERR on the remote gauge, and COOLANT LOSS on the generator’s visual display. Sea Ray is instructing its customers to NOT RESTART the generator if a 62 ERR or COOLANT LOSS display is given.

If your generator shuts down and displays this fault code, DO NOT RESTART YOUR GENERATOR and contact your local Sea Ray dealer or authorized KOHLER service representative to assess the fault and provide corrective action. The service representative will address the issues associated with the fault to ensure the unit is operating properly and safely.

KOHLER and Sea Ray are working together to enhance the information concerning this scenario and will be contacting our customer’s directly with further updates.

We at Sea Ray believe that communication to our customers is vital, and we are committed to continued quality support of our products. When issues of this type occur, the goal of your dealer and Sea Ray is to resolve the issue for you as quickly and efficiently as possible. We appreciate your choice of a Sea Ray and value you as a customer and apologize for any inconvenience this may cause you.

If you should have any questions, please contact Sea Ray’s customer service department at 865-971-6250. Customer inquiries for KOHLER should be addressed to the KOHLER Product Support team at 1-800-544-2444.

 

[Ethan's Tank]

Don't want to hijack this post Not sure what last year's was. Here is what I just received:
Sea Ray Owner,

Sea Ray® has become aware of an issue that could pose the risk of a fire hazard on boats equipped with a generator.

In two recent field events of a generator experiencing shut down during use, the consumers did not heed the specific fault code information indicating COOLANT LOSS (no seawater flow), cleared the fault code and restarted before resolving the underlying issue. Successive restarts with COOLANT LOSS (no seawater flow) builds heat in the exhaust hose and may eventually lead to a fire.

The KOHLER generator remote gauge, on generator visual display, and the generator owner’s manual provide key information when a fault occurs. The no water flow fault is shown as 62 ERR on the remote gauge, and COOLANT LOSS on the generator’s visual display. Sea Ray is instructing its customers to NOT RESTART the generator if a 62 ERR or COOLANT LOSS display is given.

If your generator shuts down and displays this fault code, DO NOT RESTART YOUR GENERATOR and contact your local Sea Ray dealer or authorized KOHLER service representative to assess the fault and provide corrective action. The service representative will address the issues associated with the fault to ensure the unit is operating properly and safely.

KOHLER and Sea Ray are working together to enhance the information concerning this scenario and will be contacting our customer’s directly with further updates.

We at Sea Ray believe that communication to our customers is vital, and we are committed to continued quality support of our products. When issues of this type occur, the goal of your dealer and Sea Ray is to resolve the issue for you as quickly and efficiently as possible. We appreciate your choice of a Sea Ray and value you as a customer and apologize for any inconvenience this may cause you.

If you should have any questions, please contact Sea Ray’s customer service department at 865-971-6250. Customer inquiries for KOHLER should be addressed to the KOHLER Product Support team at 1-800-544-2444.

This is interesting, I got the same error july 4th night. after a day of trying to get the kohler to stay running. Of course during the initial 10secs it was running, it always kicked a UU error. My battery voltage was low due to old batteries, so I gave up that battle.

After the firework show, on the way to find a transient slip while underway, my wife decided to try the generator again so we could use the grill. I was suspecting with the engines running, I got full 13v on the batteries, it cranked up and stayed up after anchoring and turning the engines off. Kicked on the battery charger and grilled some food while running AC and whatever else was needed. I thought it was strange whenever something was powered on, like the genny was revving up or down...thought it might have been normal. After about 45mins of running, the genny just stopped running and produced the 62 error. It was 430AM by that time, so I called it a night.

We tried again the next day on the voyage home and the genny worked fine the entire way home.

Bay's B, how did you receive the msg from searay/kohler? I never got one and my sea ray is aware I'm the 2nd owner of this vessel

 

[stephenm27]

Bay's B, how did you receive the msg from searay/kohler? I never got one and my sea ray is aware I'm the 2nd owner of this vessel

I, too, am a second owner but still received the notice via email from Sea Ray (searay.com) a few days ago.

Outlook/MS Exchange (outlook.com) had placed it in the 'Junk Email' folder and I happened to be looking for something else when I found it...

 

[Ethan's Tank]

I just called Kohler and its only for any EKD models that its affecting, although mine is a 5ECD and since I got the error, they said that a 62 error is a low coolant and it should not be over ridden and needs to be addressed.

Just FYI...