Potential Generator Issue - Advice needed

Docjason

Docjason

Member
Jul 8, 2015
155
Clearwater Beach
Boat Info
Currently Boatless
2006 44 Sundancer (SOLD)
2001 Donzi 39 ZSC (SOLD)
Engines
8.1
Bought a 2006 44da last summer. Everything worked fine. Having intermittant issue with the gen. 2nd weekend with the boat, I went to start the gen and NOTHING... no turning, no cranking, nothing. Took boat out for a ride and 30 minutes later it starts with no problem. Has been working fine for the last 5 weekends and fires right up. Had "house" batteries replaced today by our local MM service dept. Get a call saying that the batteries are in but they wanted to know if I had been having any issues with my gen, as after they installed the batteries it was dead. not even a readout on the digital display in the engine room. Told them about the previous issue as it sounded exactly the same and asked if it could be that the gen battery was somehow in-line with the house batteries and just needed a "charge". Was told that the battery for the gen is always isolated from all other batteries and that it would never be the case. Now, just so you, i hate the word "never". I asked if could be possible and was told "I have my master mechanic certification and that it would not be possible.

Now, while not the most mechanically inclined person, the logical explanation for the first time was that the run charged the batteries to the point where the gen battery came back to an appropriate charge where it would crank and fire the gen.

Any input would be welcomed before I have the "generator guy" at MM start on it. Also, I'm heading down tomorrow and will be testing it out and if it doesn't start, will take the boat out for a cruise and then give it another try.
 
My 2006 52SB has a great owners manual with wiring diagram. You can probably download yours from the sea ray site. I don't have a generator battery - just port and starboard banks. Generator is on port bank
 
BeeBoating said:
My 2006 52SB has a great owners manual with wiring diagram. You can probably download yours from the sea ray site. I don't have a generator battery - just port and starboard banks. Generator is on port bank
Click to expand...

When I was down in the boat topping off batteries last weekend, it looked to me like the 3 port batteries were all wired together and wondering if its the same setup. I pay closer attention tomorrow
 
Does not the boat have three battery switches?
Do you keep your boat on shore power and the AC Converter on at all times when the boat is not in use? The AC Converter should be a 3 bank charger.
I would say you have a previous owner mod issue if the generator battery is wired to another bank; that would be a pretty hazardous situation should one want to work on the 12V wiring and expecting that the battery switch turned off the current.....
Regardless, a couple of things; one - There may be an issue with the AC converter which should be a 3 bank charger, in that, the charging of the generator's battery is not happening; Two - something is draining the generator's battery down when sitting idle.
Quite possibly may be some wiring issues as well as battery health issues.
 
Mine would start with remote only sometimes and start most of the time at the generator itself. When mechanics went down to check, the gen battery sides were swollen out. They installed a new batt and no more issues. I was told the sensors and solenoids on the gen were 12 volt sensitive. Works great now.
 
Docjason said:
Was told that the battery for the gen is always isolated from all other batteries and that it would never be the case. Now, just so you, i hate the word "never". I asked if could be possible and was told "I have my master mechanic certification and that it would not be possible.
Click to expand...
You are very wise. Saying "I've never seen it that way" is very different than saying "It's never done that way." A LOT can happen from the moment a boat leaves the building room floor, and it tickles me to no end that there are both laypeople and "certified" professionals who disregard that.

I'm with you on the troubleshooting logic, though--start with the simplest (battery too weak to keep a charge) and work up to the more complex (faulty charger, faulty wiring/off-standard wiring).
 
Do you know what size your generator is? If you have the 10kw kohler model then the boat certainly came from the factory with a separate dedicated battery to start the generator. If your boat was equipped with the 7.3kw model then it may share the starting duty with the port side "house" batteries. If your boat has factory cockpit a/c then it will have the 10kw model. I bet you have a separate battery for your generator and it is old and tired and that is causing your problem.
 
I know my boats much older smaller and different but I always wondered. My gen battery is stand alone. The only way it charges is if the genny is running. I have 3 banks starting and house (2 batteries each and both banks connected to internal charger) and then the genny battery. Not connected to anything but the generator. I do have 3 battery switches.
 
Just got back and found that the gen is isolated from the other port batteries. Thinking that the new battery that was installed was not fully charged. Got to the boat on Friday and tried to fire the gen.... nothing... Started engines, went on a nice 1 hours ride, docked and thought I'd try it again and presto. Fired right up. No issues the rest of the weekend. Spoke with the service manager at MM and he said that the battery must have been dead when they put it in and running the boat charge it up.

As far as gen, it is the 10KW Kohler.
 
UPDATE>>>

Docjason said:
Just got back and found that the gen is isolated from the other port batteries. Thinking that the new battery that was installed was not fully charged. Got to the boat on Friday and tried to fire the gen.... nothing... Started engines, went on a nice 1 hours ride, docked and thought I'd try it again and presto. Fired right up. No issues the rest of the weekend. Spoke with the service manager at MM and he said that the battery must have been dead when they put it in and running the boat charge it up.

As far as gen, it is the 10KW Kohler.
Click to expand...


So the problem has been continuing. Get to boat a few hours before going out and turn on battery chargers... gen still won't start. Run boat for 1.5 hours, gen fires right up. Called and spoke with service manager at my local MM and he tells me he thinks it may be a faulty battery charger. Send master mechanic to my dock to check it out. Says gen shows power all of the way to it but won't start. This last weekend, the gen won't start at all regardless. Battery showing 13.7 volts. Won't even turn over. In fact, can't even get the digital display in the gen itself to show anything. Super perplexed so I have dropped it off at the marina as the "mobile guy" says the "gen guy" needs to look at it and they only do that at the marina. I've check all of the connections and can't find anything loose or disconnected. Any advice greatly appreciated
 
Baby steps. Tou "should" have a + and - for the gennie battery. Connect a new battery or a jump pack to those directly and see if it starts from the gennie switch panel on the gennie itself.

let us know.
 
Xplicitlnck said:
I know my boats much older smaller and different but I always wondered. My gen battery is stand alone. The only way it charges is if the genny is running. I have 3 banks starting and house (2 batteries each and both banks connected to internal charger) and then the genny battery. Not connected to anything but the generator. I do have 3 battery switches.
Click to expand...

Jonathan,
Your boat is the same as mine. But your battery charger is likely a 3 bank unit that also charges the generator battery. There should be a wire from the charger to the battery side of the generator battery switch that will charge the battery. That is how mine is wired, so you don't see the "charger" wire at the battery itself.


Sent from my iPhone using Tapatalk
 
Hate to suggest something so basic, but if the generator battery reads 12-13 volts and does not drop below, say 10.5V during cranking, then, the most obvious thing is dirty or loose battery clamps.
 
dpmulvey said:
Baby steps. Tou "should" have a + and - for the gennie battery. Connect a new battery or a jump pack to those directly and see if it starts from the gennie switch panel on the gennie itself.

let us know.
Click to expand...

Did that this last weekend...nothiing
 
h_gerry said:
Jonathan,
Your boat is the same as mine. But your battery charger is likely a 3 bank unit that also charges the generator battery. There should be a wire from the charger to the battery side of the generator battery switch that will charge the battery. That is how mine is wired, so you don't see the "charger" wire at the battery itself.


Sent from my iPhone using Tapatalk
Click to expand...

Will check that out. I thought it odd that I didnt see a charger wire directly on the battery
 
fc3 said:
Hate to suggest something so basic, but if the generator battery reads 12-13 volts and does not drop below, say 10.5V during cranking, then, the most obvious thing is dirty or loose battery clamps.
Click to expand...

Took all of, checked, and cleaned as a precaustion. Showing power all the way to the gen but nothing once it hits the gen proper
 
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