New Kohler Genset shuts down

[M99]

I have a new (10 hours total time) Kohler 5K Fuel Injected Genset on my older SeaRay 300 SD. It usually works fine. But if it is not run for a few days, after starting it from the Remote Panel, it will run for about a minute or a bit less, then shut down. It is running out of fuel, because the fuel line is long and as soon as the Generator senses a fuel pressure drop, it shuts down. It will start right up again and run fine AFTER I have to get down in the engine compartment to re-set the error code it throws. I have called Kohler and their remote panel does not allow the error code to be reset from the Panel. Its really difficult to do that reset without pulling the rear seats out of the boat and at Sea, I wouldn't even try it. My only thought is to give up and add a secondary priming fuel pump in the line that I can activate prior to Generator start up after it has sat for a few days. Kohler doesn't seem to have any software update to fix this problem. There are check valves in the line an I have tested them. This generator replaced a carbureted one and there was never a problem like this with the carbureted unit. Anyone have any thoughts or similar experience with these new fuel injected eco generators?
Thanks.

 

[dwna1a]

Have you checked the oil level? They have a low oil shut off

 

[JimG]

So you're sure its shutting down because of fuel? What is the error code?

I can reset most error codes on mine by flipping the battery switch to off and then back on.

 

[JimFromMD]

Its not clear from your response here, but once you start it a second time does it run fine from then on?

Not sure how your setup is, but my fuel line runs from the tank, to a big mercury spin-on water separating fuel filter, to the kohler fuel filter, to the fuel pump, then to the carb bowl. In my case, the spin on filter is level with, or slightly higher than the generator itself. I assume as long as there is fuel in that big filter, the pressure would be fine and fuel should easily be pulled by the kohler pump from the spin-on filter. I would assume that the spin-on filter would be a big enough of a buffer to keep the pump supplied while more is drawn the long distance from the fuel tank (though in my case its a matter of 2 feet from tank to fuel bowl.)

Just some thoughts. Maybe describe your setup and/or provide some pictures too?

James

 

[M99]

So you're sure its shutting down because of fuel? What is the error code?

I can reset most error codes on mine by flipping the battery switch to off and then back on.

Thanks for that tip. I have not tried turning the Battery Switch off and back on to re-set it. If that will work, it might be an easy solution since that switch is easy to get to. The error code is the one for out of fuel.

 

[M99]

My set up is pretty much the same as yours is other than I have an injected Generator. If it was carbureted I don't think I'd have a problem since the fuel in the carb bowl would last long enough for the pump to re-fill the line. Once I re-set it and re-start it, it runs fine and I can shut it down and re-start it at will without further problems. But after sitting for a couple days, then the same situation occurs when the fuel bleeds down from the lines. I tried removing the large Sea Ray filter since it has its own fuel filter, but that did not help. The fuel in the spin on delayed the shut down, but there would still be an air gap before fuel was pulled from the tank.

 

[kaz911]

I had the same kind of issue due to air getting into fuel lines on the Kohler. It does NOT like that. It was a tiny leak in the fuel line where it would suck in air as the fuel cooled down after running. Hot fuel takes more space than cold fuel - and that was enough to suck in air. After going through all the fuel line with a lot of light - I spotted a place on the fuel line where there was just a hint of fuel. I'm waiting for a replacement fuel line - but I stopped the worst part of the problem with a bit of Rescue Tape (Silicone tape that fuses with itself on each turn - and is heat & fuel tolerant)

 

[Danny Troy]

I had a similar situation on my Kohler, where it would die after a minute or so. Changing the plugs and fuel filter fixed it. I'm not saying that's the answer, but it's worth a try.

 

[M99]

Kaz911, I'm pretty sure that is the same problem I am having. I have looked very carefully at all the lines and found nothing, but the lines could use replacement. They are very difficult to get to though at the tank. I've pulled most of the fitting I could find apart and put thread sealer on them and torqued them properly. The plugs and fuel filter are also new. The Kohler software is too sensitive to any air in the line and the problem could easily be resolved that way if they just allowed a few seconds delay before shutting down with an error code thrown. I think I have resolved my particular problem the hard way though. I added a small uplift fuel pump that only puts out about 7 psi on the out flow side of the original Sea Ray filter and installed that again. I wired that fuel pump back to the generator panel, where I can engage it for about 30 seconds prior to starting the generator and let it run for a minute or two while the fuel flow stabilizes. The Kohler pump puts out 39 psi at very low volumn so it can't pull the fresh fuel in fast enough until pressure is stabilized in the line. It was a pain to do that installation, but I'm near 100% sure its a permanent fix. I won't be able to tell until I wait about a week to try to start it again.

I did try the battery shut off idea, but it did not re-set the error code on my boat.

 

[kaz911]

I hope you got it it is a darn annoying issue. But every issue on a Kohler is annoying IMHO. It is a POS generator when it fails as their codes are not to any use - and it seems like it was designed by someone who have never operated or diagnosed on an engine ever in their life. I now run my generator at least 1 hour every two weeks - and EVERY time I take the boat out it runs at least as long as the main engines. The generator likes that much more than not being used.

 

[M99]

I'm pretty sure that I finally solved it. I added a very small 7 psi / 34 GPH uplift fuel pump just ahead of the original Sea Ray Fuel Filter for the Generator, and wired it back to a switch next to the generator start switch at the Power Panel. I turn that on for about 30 seconds prior to starting the generator and leave it running for the first minute, then shut it off. That keeps the fuel line full and under low pressure until the 39 psi Kohler Fuel pump can keep it flowing. A really dumb need for that workaround for bad software.

 

[my DOG HOUSE]

I hope you got it it is a darn annoying issue. But every issue on a Kohler is annoying IMHO. It is a POS generator when it fails as their codes are not to any use - and it seems like it was designed by someone who have never operated or diagnosed on an engine ever in their life. I now run my generator at least 1 hour every two weeks - and EVERY time I take the boat out it runs at least as long as the main engines. The generator likes that much more than not being used.

The best thing you can do for any Marine Generator. Run it!