Cold Starting Kohler 5E

[320Bob]

Bob,

On my 340, with a 5E, it is physically impossible to hold the PREHEAT/STOP switch and START switch at the same time. They are both located on opposite ends of the same rocker switch.

My manual shows (Fig 6.9.1) two separate switches on the Cabin DC Distribution panel so either my manual is incorrect or your 340 and my 320 have different panel configurations. I can't get to my boat to verify either way.

 

[carterchapman]

Bob,

I'm not going to get to mine until mid-week - but now that I think about it, my PREHEAT switch may be on the middle switch on my panel - opposite the ON rocker.

So I think I'm buying the beer when I see you...

 

[320Bob]

Bob,

I'm not going to get to mine until mid-week - but now that I think about it, my PREHEAT switch may be on the middle switch on my panel - opposite the ON rocker.

So I think I'm buying the beer when I see you...

Get out to the Gulf and take a right. Then make a right at the Mississippi. Take a slight right at Grafton go about 270 miles just past the Dresden lock to mile mark 273.3 and I'll be in slip 39 waiting for that beer!:smt043

 

[firecadet613]

I know I have a different brand, but on my 5E there is no Preheat. It just has the electric choke, which if not adjusted properly, will make it very hard to start.

 

[carterchapman]

Darn Bob,

Is that North or South on the "Missislopi"? Let's get 48'ers down where it's warm year around!

 

[jason78]

Thanks for the help everyone. I believe I will start with the choke and go from there. I will post my findings.

Jason

 

[KevinS]

My 340 (2003) has a 5E and the rocker switches are as described where the Start is on the top end of one and Preheat/Stop is on the bottom of the same switch - they cannot both be activated at the same time as they are opposite ends of the same switch.

Several years ago during my captain orientation delivery at MarineMax, they told me to press the preheat side for several seconds when cold-starting the genny, followed by the Start side until you hear it start (but no too long as also noted).

I don't know what the preheat does but it has worked well for me and I've never had trouble starting it. (avoiding clogged strainers and other gen problems notwithstanding)

 

[Scupper Guppy]

Kohler gas gensets have NEVER had a preheat function, regardless of the model or year. Their start/ stop switches have always been just that... 'start' and 'stop'. Cold starting is aided by some form of electric choke on carbureted models, or fuel enrichment on the fuel injected units.

If your boat has a switch marked 'preheat', it will have no function on the gas Kohlers. Most likely the preheat switch will have no wires attatched. If it does have wires. they are probably dead-ended somewhere.

So if your Kohler gas genset starts quicker when you push the preheat button, you're probably just imagining it. And if a 'sea captain' says that you need to preheat your 5E, you need a second opinion from someone more experienced.

 

[320Bob]

Kohler gas gensets have NEVER had a preheat function, regardless of the model or year. Their start/ stop switches have always been just that... 'start' and 'stop'. Cold starting is aided by some form of electric choke on carbureted models, or fuel enrichment on the fuel injected units.

If your boat has a switch marked 'preheat', it will have no function on the gas Kohlers. Most likely the preheat switch will have no wires attatched. If it does have wires. they are probably dead-ended somewhere.

So if your Kohler gas genset starts quicker when you push the preheat button, you're probably just imagining it. And if a 'sea captain' says that you need to preheat your 5E, you need a second opinion from someone more experienced.

Read Post #19

 

[Stray Cat]

What Bob wrote in post 19....perhaps it works different on a Flubadub Deluxe...right hand column, half way down the page, text is in all caps...pretty much sums it up

 

[jason78]

As expected after not being able to start the genny last time, it fired right up this time in 2 seconds and it was cold at that. I let it run a while and shut it back down. Maybe this genny is smart enough to know when I really need it and refuses to start then. I am going to try and adjust and lube the choke and linkage as has been suggested.

I do know I need to get this thing fixed. Part of selling my wife on a bigger boat was that we could be more comfortable using the boat in the winter with the genny and heat. So far it has failed to start whenever I needed it. It is making me look bad :smt009

Thanks and I plan to get down there and maintain it as soon as my back starts feeling better so I can get down there.

Jason

 

[Windjammer]

Generator will not stay running when I try starting from the panel inside the cabin. Able to start manually from the engine compartment but the choke is not closing all the way on a cold start....
Other 5e's that I've seen have a round plastic knob with two screws - loosen the screws and rotate the knob to adjust.

Mine has a square black plastic cover with two screws (see pic) - so how do I adjust the choke?

 

[Vince_nj1]

I didnt have a cold start problem, but I did have a problem with unit shutting down after running for a short time. My problem turned out to be a faulty relay.

I tried to get a Kohler dealer to fix it under warranty but he wouldnt service the unit unless I agreed up front to pay him for any charges that were disallowed by Kohler. (some warranty huh?) In the end I bought the relay and installed it myself. I think relay and shipping was less than $15.00. I don't know if this is your problem, but you should be aware of it and you should also beaware of a recall on the exhaust.

See the link below.

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

http://clubsearay.com/forum/showthread.php?t=23752&highlight=Kohler

 

[mhtimber]

I have the same generator and it too has been problematic since day-1; the major issue being the electric choke not disengaging.

The dealer had to bring in a Kohler tech to get the thing running and then it still was very difficult to start, after three visits by the tech rep.

My current mechanic has been the best with it so far, and after he readjusts the choke it starts and runs fine; though it needs to be adjusted at least twice a season.

When the choke is sticking I just raise the ER hatch enough to stick my head inside and manually push the choke lever back and then the engine smooths out and runs fine thereafter. It's more of nuisance issue than anything.

I chalk it up to small gas engines often being cranky and fussy.

Jeff

 

[firecadet613]

You should be able to loosen up the screws and manually adjust the choke by turning it.

 

[carterchapman]

Windjammer - when we finally get some warm weather, let's take that square cap off again and see what can be adjusted under there...

Scott - is your '07 like Windjammer's '06 or do you have a 5ecd?

 

[Windjammer]

Windjammer - when we finally get some warm weather, let's take that square cap off again and see what can be adjusted under there...

Scott - is your '07 like Windjammer's '06 or do you have a 5ecd?

I hear ya about some warmer weather...I did go ahead and order the "choke repair assembly" kit which includes the heater, choke housing, etc, etc as "plan b".

 

[320Bob]

I just talked with the Service Manager at my Sea Ray dealer about what additional maintenance need to be done to the boat that the PO did not do. He suggested that I keep a spare spark plug for the Generator engine on board since he has found that the Kohler generator spark plugs tend to get fouled causing starting problems. When the plug is replaced, the starting problems go away.

 

[Chris R]

I'm having the same issues. By the way, I just replaced the plugs yesterday. When using the manual start on the unit itself, it starts and runs fine (under load, no load, etc.). However, when I shut it down, then flip the switch to "auto" and try to start from inside the cabin on the distribution panel, it runs for about 2 seconds and dies. Doesn't matter if it is fully warmed up or stone cold.

 

[mawyatt]

I'm having the same issues. By the way, I just replaced the plugs yesterday. When using the manual start on the unit itself, it starts and runs fine (under load, no load, etc.). However, when I shut it down, then flip the switch to "auto" and try to start from inside the cabin on the distribution panel, it runs for about 2 seconds and dies. Doesn't matter if it is fully warmed up or stone cold.

Not sure if this helps but the shut down can happen under an Aux input condition. Had this with the CO alarms when service had disconnected the network interface which caused the generator to shut down, got an error message which I traced to an Aux input.