Kohler 5e troubleshooting

[stg099]

Hope everyone is having a great boating season thus far. Looking for some thoughts/help in diagnosing my Kohler 5e in a 2004 280 Sundancer. Background: generator was running great with no issues prior to this issue popping up.

Symptoms: When I flip the "On" switch on the remote generator panel, the LED light in the Carling switch flashes on and off, (Previously it would light up solid). In addition, the light in the Generator start switch flashes. While this occurs, I can hear a relay clicking open and closed on the relay board on the generator. I presume that this relay should either be open or closed fully, not clicking like it is now. In addition, if I attempt to start the generator from the start/stop switch on the gen itself I get a brief rapid clicking similar to a low battery situation, however the battery has been checked and does not present any issues. (this battery is shared with one of the main engines and performs flawlessly there).

Curious if this could be driven by one of the Carling switches gone bad. From what I've read it sounds like when a relay doesn't get appropriate voltage or ground, it can "click" on and off.
Also curious if it could be the relay board itself. I was able to source new carling switches from FP marine, so I was going to try that first, then call in the Kohler tech if that doesn't change the symptoms. If anyone has any thoughts as to why the relay would be "opening and closing" like this I'm all ears, as it may help me to diagnose the issue.

Thanks!
John

 

[Cocktail Time]

Relay clicks to open fuel solenoid, your symptoms sound like a bad battery, have you double checked the positive and negative connections on both the battery and starter? A little corrosion or a loose terminal will cause low voltage even when battery is fully charged.

 

[hottoddie]

Also check the ground connections on the generator as well as the connections on the generator starter.

 

[stg099]

Update. The generator will start and run when started locally, and the remote switch on the panel in the cabin is "off", however, even though the gen is running, I do not get any voltage at the panel when I switch to the gen from shorepower. Mechanically the gen seems to be running fine.

If the remote "on/off" switch is set to "On", all I get is a flashing light on the "On" switch and the "start/stop" switch, and cannot start the gen locally or remotely, just clicking. I tested the power coming into the "On" switch while it is turned "off" and it's 13.5V, but when I flip the switch to "ON", it drops to 6v and fluctuates a little as the relay in the gen control board "clicks". I'm about to order a Kohler control board, but was curious if anyone has experienced anything like this in the past?

 

[hottoddie]

I recommend going back to basics. The symptoms sure sound like bad battery or connections. How old is the battery? Are the cells full of water/acid? If the battery voltage is too low the remote panel is the first to stop working. The 13.5 volts is not as important as voltage under load.