Does Your Generator Have a Mind of Its Own?

S

Sweet Baby Ames

New Member
Jul 14, 2009
6
Covington,La.
Boat Info
310 Sundancer
Engines
Tein 350 Mags
Ever since I bought my boat, the genreator has had a problem where it starts on its own. The dealer says it is a software issue but he cant seem to fix it. He is on his 3rd try now. The only way to solve the problem is to leave the batteries off or the main braker on the generator panel off. It is a Kohler generator. Anyone have this problem?
 
Software issue? They must be making some crazy new gensets these days. I'd love to hear the details on how this could even be possible.

You must have a start switch, right? Energizes the solenoid, which energizes the starter...I can't for the life of me understand how "software" could bypass the starting circuit and energize the starter.

I'm calling BS on your dealer...
 
I have a control in the cabin with a digital display and start stop buttons. They blame it on that. My O&M manuals don't have any info on the control display.
 
I read a bit on it, electronic start/stop controls... I may stand corrected. This type of problem is certainly way above my pay grade; How have they decided it's a programming problem, and ruled out a faulty board at the keypad or control unit?

If it were my boat, and the dealer has had three tries to fix it, I'd insist that they get a Kohler technician out to the boat NOWWW. Of all things that need to have a failsafe- this would be it. There should be NO WAY that the generator could start by itself through a failure of the electronics.

What if you had the boat dry stored and the generator started itself...
 
Sweet Baby Ames said:
Ever since I bought my boat, the genreator has had a problem where it starts on its own. The dealer says it is a software issue but he cant seem to fix it. He is on his 3rd try now. The only way to solve the problem is to leave the batteries off or the main braker on the generator panel off. It is a Kohler generator. Anyone have this problem?
Click to expand...

It is programming issue. Some of the units are programmed to start itself and recharge batteries when voltage drops below certain level. I think it was done for boats what are kept on moorings and they are no access to shore power - remember that bilge pumps are hard wired to batteries and they will use battery power with switches off or boat may sink during heavy rain with dead batteries. I am not sure if that settings can be changed by user (check your manual), but kohler techs can easily disable that feature.
 
Thanks for the help. That makes sense. As far as trying to disable it, my manual doesn't have any specific info about the controller. It only lists it as an accessory to the generator. I'll look into it some more. Maybe it can be disabled from the main control on the generator itself.
 
To isolate it to the generator, the remote panel harness can be unplugged at the generator. This will isolate the generator. The only way to start/stop the generator will then be at the generator which is not a good solution.

This sounds like a charging software issue or a short to the remote panel. In either case it is a dangerous condition and your Sea Ray dealer or Kohler should step up and exorcise the ghost off your boat.

-John
 
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When we took delivery March 08 we thought we had a unique error code on the generator (turned out to be nothing), the cap't mentioned a recient delivery where the gen set started on it's own and ran while the owners were away. They returned to an empty gas tank thinking someone had taken the boat out or stole the gas. They refilled only to find out the next week when they arrived the gen running and with a bunch of hours logged!! MM/Kohler took care of the fuel cost and did a software update...not sure if the owners got any credit for the generator "use"!
 
OK, stopped by the dealer today. He has the Kohler rep coming to "re-flash" the controller. But get this, he said he has still had problems where if the batteries are low and the generator comes on it could re-boot the controller and have the same problems all over again. Watch out for these things!
 
Watch out? No way...If Kohler can't guarantee a fix I'd tell 'em to take it out and put in a Westerbeke. Brand new boat- don't settle for anything that doesn't work properly.
 
tobnpr said:
Watch out? No way...If Kohler can't guarantee a fix I'd tell 'em to take it out and put in a Westerbeke. Brand new boat- don't settle for anything that doesn't work properly.
Click to expand...

you can easily fix it by turning off generator battery switch :) for them it could be a proper way to operate - low battery ---> recharge system. Generator battery is not connected to battery charger! Once goes down - you will need external charger or jumper box :)
 
I've witness the same problem twice on my Kohler 5ECD. I'm irritated by it. Worried about leaving the battery switches on when she's unattended. But, it's too low on the priority list to tackle.

Let us know if you get a resolution! :)
 
Any responses? Just happened to us...
 
This may be a trigger that your battery charger gives to the generator and not a generator issue at all. Look into the battery charger settings.
 
ttmott said:
This may be a trigger that your battery charger gives to the generator and not a generator issue at all. Look into the battery charger settings.
Click to expand...
The boat was connected to shore power the entire time. Could it still be a potential cause?
 
I'm pretty sure that Kohler resolved this some time ago. The basic issue was a "feature" which sensed the battery voltage getting falling below a certain point which then triggered the generator to start up and run.

If you had it plugged into shore power something is not right since your charger would have been keeping the battery charged. How old is the generator battery?

The battery and/or the charger are the first places to look. Put a multimeter across the positive cable at the generator and ground to check the voltage with the charger on and off.
 
This is an old thread but it happened to us yesterday. Plugged into shore power with Batt charger on with 4 new AGM’s and new AGM charger, The gen started by itself, What a surprise!! Actually the gen had 60 hours and now 85 so we think it has been doing this when we are not there, scary. We have only used the gen a few times to use microwave. Contacting MMax, Koehler & Ghost Busters today
 
I had this issue and was scratching my head for a while. I am pretty sure its what was stated earlier - when the voltage dropped, it comes on automatically. I have two weak batteries and when starting the motors, i noticed a large voltage drop and the gen turned on by itself, so that what i am thinking...
 
Three Seasons said:
This is an old thread but it happened to us yesterday. Plugged into shore power with Batt charger on with 4 new AGM’s and new AGM charger, The gen started by itself, What a surprise!! Actually the gen had 60 hours and now 85 so we think it has been doing this when we are not there, scary. We have only used the gen a few times to use microwave. Contacting MMax, Koehler & Ghost Busters today
Click to expand...

No battery switch on your generator?
 
Kohler has "Standby" logic on its control board. Standby means auto start when either shore power or battery voltage drops. While this is okay for Residential generators it is downright creepy on boat generators. Who wants their generator starting and running when no one is around?

Allegedly it can be programmed to disable Standby mode.
 
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