Generator mystery

Rob WIcha

Member
Nov 14, 2019
129
Florida
Boat Info
2009 330DA
Engines
Twin 496 Mercruiser Axius
2009 330 DA / Kohler 5 Ecd. So went to boat yesterday to do a few maintenance things and generator control panel in cabin was beeping, didn’t think to much of it just turned batteries off and back on all good. Fix a few other things and went to start engines and starboard engine had a hard time idling. I’m like great now what? Then also noticed that the generator had a hard time starting and running. Then after checking things noticed starboard fuel tank was completely empty. Hum that strange as last weekend both tanks were at 1/4. Ok got a 5 gal gas can, had to make 3 trips to gas station to get 15 gals in boat so gas gauge start to read a slight bit of gas in tank. Engines started up fine went to marine and filled it up. Generator had a bit of a hard time starting as well as there was no gas but after a few try’s all good.
At this point also noticed generator had 60 more hours on it from last weekend.
After many guess on what happened ( someone’s been on boat using genny, which makes no sense since it’s on shore power. Maybe someone’s siphoned all the gas out ) I watched my cameras back and saw genny started up by itself and ran for 3 days straight till fuel tank was empty. Ok WTF? First I do leave the batteries on so genny has power and could start. Second I thought genny would not be able to pull gas from tank under a 1/4 full as fuel pick up is designed this way so you can’t run tank out of gas. I also noticed that from control panel in cabin I can start genny but can not stop it, have to use the switch on the unit itself. Maybe the control panel has a problem? Any thoughts?
 
Thanks. Today the control panel shuts it down like it should. Weird.
 
I expect nothing less from a Kohler! :D
 
I just posted this in another thread.

Allegedly all modern Kohler generators have a "standby" mode built into their logic boards. Standby means that if it sees a drop on AC line voltage or DC voltage.....the unit will auto start and run until either condition returns to a normal state. While this makes perfect sense for a Residential generator.......it is downright creepy on a boat generator. The thought that a boat generator will run on its own with no one around.....is just disconcerting and will drain the supporting fuel tank.

Since Kohler uses the same logic board on both Residential and Marine units.....it isn't a surprise that the "ghost in the machine" is named Standby. Allegedly, Standby mode can be permanently turned off by a technician.
 
But would that happen? Wouldnt the AC switchover switches isolate the genset from knowing if Shorepower is on or not?
 
I don't think that is the case. I have a camera that is wired to the same circuit as shore power running to boat and camera did not lose power. I was able to view back when genset started and saw I ran for 3 days.
 
I have no first-hand knowledge of Kohler, but in general: On a marine unit the standby circuit must monitor the DC voltage (whereas on a home unit it monitors AC). When you want to use this feature you manually change your AC panel to be supplied by the generator, then put the generator into standby mode. You go about life using power and draining the batteries. When the batteries get low, the genset starts and recharges the system, and shuts off.
 
Check this out;
http://www.clubsearay.com/index.php?forums/general-maintenance-repair-questions.21/

Had same issue, noticed gen had 25 more hours on it. MMax is going to reprogram gen settings to illuminate the standby mode. This tech is great for your house but not a boat. There are stupid stickers all over boat protecting the clueless but there is nothing about standby mode.

According to the Kohler Service Manual, there is a configuration parameter in the ADC (controller) called "Unit Configuration". From the manual text:

Unit configuration (Uc). This parameter sets the
generator set type: marine, standby, or mobile. The
setting for the 5/7.3ECD and 4/6EFCD is Uc00, marine.

Notice the "standby" value...I wonder if you the units that are auto-starting are simply mis-programmed with this value? Reprogramming takes about 30 secs to do. If you can read and push a button, you can do it. Better yet, for anyone whose had this condition occur, you might be able to confirm your setting is incorrect...
 
According to the Kohler Service Manual, there is a configuration parameter in the ADC (controller) called "Unit Configuration". From the manual text:

Unit configuration (Uc). This parameter sets the
generator set type: marine, standby, or mobile. The
setting for the 5/7.3ECD and 4/6EFCD is Uc00, marine.

Notice the "standby" value...I wonder if you the units that are auto-starting are simply mis-programmed with this value? Reprogramming takes about 30 secs to do. If you can read and push a button, you can do it. Better yet, for anyone whose had this condition occur, you might be able to confirm your setting is incorrect...

Several of the models require a tech to change a board setting or use a PC to interface to the control board to change the setting. The newer models can be set using the technique you described. Allegedly, new control boards come pre-configured for Standby. In the event a control board was replaced at some point.......the Standby ghost shows up when it wasn't there before.
 
The newer models can be set using the technique you described.

My '09 5ECD has the ability to configure this setting directly via the ADC 2100 (controller). All models that utilize this controller (4EFCD/5ECD/6EFCD/7.3ECD) should have the same configuration capabilities per the Kohler service manual.

The 2100 has non-volatile storage that retains all configuration settings (system output voltage, phase, unit configuration, engine type, and can bus protocol to utilize. So if a new controller board is installed, it's very possible the unit configuration value is incorrect as the 2100 is also used in other applications (mobile) where this value would be valid.

I think the OP's unit is a '09 5ECD so he should be able to configure/verify this...
 
Screenshot 2020-06-24 05.28.43.png


Ok found it, I will check configuration in next few days.
 
How much stuff can you guys run while on generator? it seems if I have A/C and Battery charger on then add Electric Grill genny sounds like its struggling. I also have a bit of a problem with sucking up sea weed then it starts to get hot. last time out the sea strainer was full, I emptied it ran genny again started heating up then found big sea weed clump clogging thru hull from under boat, still seems to run about 210 degrees. I'm doing a full tune up this weekend as it has about 90 hours now since it ran for 3 days straight on its own (I still can't believe that happened).
 
How much stuff can you guys run while on generator? it seems if I have A/C and Battery charger on then add Electric Grill genny sounds like its struggling. I also have a bit of a problem with sucking up sea weed then it starts to get hot. last time out the sea strainer was full, I emptied it ran genny again started heating up then found big sea weed clump clogging thru hull from under boat, still seems to run about 210 degrees. I'm doing a full tune up this weekend as it has about 90 hours now since it ran for 3 days straight on its own (I still can't believe that happened).

I've never had any issues running a full load on the generator. If the water heater, microwave, A/C and grill happen to be simultaneously on, I might hear it "react" to the load--but it doesn't struggle or shutdown. It runs fairly consistently at 196 F degrees. It has ~750 hrs on it, 350 of which we are responsible for.
 
196? Where are you? Maybe here in Fort Lauderdale because of warmer water, 85 last weekend is why I’m running hotter or maybe I should check my thermostat.
 
How much stuff can you guys run while on generator? it seems if I have A/C and Battery charger on then add Electric Grill genny sounds like its struggling. I also have a bit of a problem with sucking up sea weed then it starts to get hot. last time out the sea strainer was full, I emptied it ran genny again started heating up then found big sea weed clump clogging thru hull from under boat, still seems to run about 210 degrees. I'm doing a full tune up this weekend as it has about 90 hours now since it ran for 3 days straight on its own (I still can't believe that happened).

Mine runs good with A/C/Fridges/Electric Grill/Microwave/charger. But add the hot water heater and it can overload if the microwave is on.
 

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