Generator Replacement

Jims380DA

Member
Mar 5, 2007
286
CT
Boat Info
2000 Sea Ray 380DA, Kohler Gen
Engines
8.1L 496 MerCruiser
Curious if anyone has replaced their factory generator. I need to replace the Westerbeke that came with the boat and would like to try another brand such as Kohler. Any feedback on the Kohler product and suggestions would be appreciated. Thanks
 
Blown rod through the block with only 130 hours on it. From the research that I have done the model I have was a problem for Westerbeke. I know the unit is no longer under warranty but I contacted Westerbeke anyway for any help or consideration on purchasing a new unit. They have been the most disappointimg company I have ever dealt with. I guess Sea Ray no longer uses them for a reason.
 
They don't use Westerbekes because Brunswick/Mercruiser has a marketing agreement with Cummins and Cummins owns Onan.

Westerbekes normally give years and years of trouble free service. Contacting them thru a dealer usually works if anything will. You don't give us boat year so I have no idea if there is warranty remaining or not. Many times the dealer can work with a factory distributor and get OEM pricing on a replacement or a reman unit.

Onan makes good gear and I would own one if I had local service.

Whatever you choose, but sure it is a company who has someone locally who can and who will service you after the sale and installation.

Changing generator brands isn't as simple as changing light bulbs. Each manufacturer has detailed engineering specification that should be met. Westerbeke is very conservative and the new generator may work with no modifications, but you won't know until you review the installation and engineering guide for whatever you select.
 
If you go with a Kohler PLEASE ask if they have their circuit board issues worked out. I have been though 5 of those little guys on my 6.5 KW and its getting old QUICK.
 
The ONE (1) upgrade, replacement or repair I've done that was smooth and caused no heartache:

I replaced an ancient 8kw quicksilver with a new Kholer 9kw. We have used it a ton, running up over 1,200 hours in less than two years. We spend 3 days a week swinging on the hook from Tampa down to Marco island (explains the hours). Not a single problem. Starts every time, keeps a good, clean field and is relatively low maintenance. On a recent trip in 96F air temp and 90F water temp, we ran it for 6 days straight 24/7. Wouldn't leave the dock without it.

Kholer 9EOZD - approx. $11k installed (diesel with sound shield, remote start and remote hour meter)
 
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Frank - What you say is true with the Cummins/Onan products. Not with gas models. Sea Ray uses Kohler now. Tried all avenues with both a Westerbeke national distributer and Westerbeke direct. Very tough to deal with and Sea Ray knows that. The model that I have has been documented as a problem unit.
 
It's unfortunate to hear the Westerbeke is so hard to deal with. I still think their gennies are the most reliable and trouble free and run for thousands of hours if maintained well. I also think they are quieter and less vibrating than the Kohler sets.
 
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7.2 BCGB 3600 rpm. I will try and post photos later. The unit looks brand new and has been properly maintained since new. It would be just as much $ to repair this unit than to replace it with a new one and no guarantee that the back end will go down the road. Everyone I talked to in the business told me to replace the unit.
 
My previous boat(Carver) had a 6.5 CZ Kohler(gas) 3600 rpm which was a pile from the day they made it. They touted the "light weight" which it showed. Had 900 hours and one rebuild and needed another before I put in a 7kw Westerbeke 1800 rpm. My complaint is that they have a manual electric choke that you had to hold until it warms up. Summer was not an issue but when the water cooled off it was a pain holding it for up to a minute. The plus side was not needing a sound shield and I think they run a little cooler without it. Just my 2 cents....
 
7.2 BCGB 3600 rpm. I will try and post photos later. The unit looks brand new and has been properly maintained since new. It would be just as much $ to repair this unit than to replace it with a new one and no guarantee that the back end will go down the road. Everyone I talked to in the business told me to replace the unit.


Aren't they 1800 rpm units??
 
The new ones are. My unit is a 3600 rpm. Can anyone with the Kohler gas models who own a newer model 38 or 40DA let me know if you are pleased with the performance of the Kohler? Thanks
 
Jim,

We have a low CO 7.5KW Kohler in our 2008 38DA. So far no issues. I changed the oil at 20hrs and they have a nice outlet with a valve that you place a hose over to drain the oil...nice feature that keeps things clean with oil changes. The sound shield is kind of flimsey and doesn't fit well, but does help with gen noise which is pretty low.

I have an issue that I thought was a gen problem. The 4 batteries were replaced (dealer let them go dry) and when the service guys replaced them the CO sensors went into alarm...so they pulled the cable to the CO sensors (all 3) and left a note for me. When I plugged the sensors back in they all alarmed, then I start the generator up and it quits after 20 sec, start again and same. I note a error code on the gen control panel which is an aux input code. Turns out the plug on the CO sensors was the network plug and not the power plug, so when I removed/recycled power by shuting down all dc power with the main solenoids the CO alarms all reset and the gen starts and runs without error code. What happened is the CO sensors are all networked together and to the generator, when an alarm activates it sends a command to the generator via the aux input to shut down...IMO nice safety feature.

Mike
 
My low CO 5e - Kohler has been great. I have never tested my carbon monoxide detector, with the generator running. Does anyone know if you test it and it is networked to the generator will it shut it down?
 
See post above. Not sure if this is true on all SRs, in fact the service guys from MM didn't know this..but my salesman did.

Mike
 
So when you test it - it should shut -down. I need to try that.
 
Frank - What you say is true with the Cummins/Onan products. Not with gas models. Sea Ray uses Kohler now. Tried all avenues with both a Westerbeke national distributer and Westerbeke direct. Very tough to deal with and Sea Ray knows that. The model that I have has been documented as a problem unit.
Have you tried these guys http://www.hansenmarine.com/ I know there has been some praise for them on this board before and they answered a lot of questions I have had in the past.....
 

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