Life expectancy of a generator

[Tawney1]

Our 61 has two 20kw Kohlers. The forward genny has nearly 5,000 hours and the aft has about 3,000. For whatever reason, the forward genny has decided it is not going to start. In fact, it will not even fire. It acts as though it is getting no power. Initially, it fired right up. I turned it off to clean the strainer. Then, when I tried to fire it up again. Nothing. Not one sound.

My question is three-fold:

1. What could be wrong?

2. What is the life expentancy of a Kohler in hours (I know this has something to do with load factors over its life span, etc.)? and,

3. If you have to replace it, how in the world do you go about it? The hatch over the generator room doesn't look as though you can fit anything half the size of a generator through it -- either to remove the old one or put in a new one--as it is roughly about 24" x 24".

Any help or input here fellows?

Many thanks,

Paul

 

[Genesis]

If it won't fire at all its either got air in the fuel lines somehow or the injection pump has failed.

Even with a totalled cylinder they'll light - just run like crap.

This assumes that it will roll over. If it doesn't roll over but the starter is engaging and good it probably got salt water in it somehow and is hydrolocked. In that case its a total.

 

[Tawney1]

Genesis,

Thanks. It will not roll-over. The starter will not engage.

Paul

 

[StratPlan61]

Paul, I can help with your Question #3:

I think my 61' MY is similar to your own. When I replaced my aft 20kw Kohler I called in Diesel Don's, LLC from Scottsboro, AL (256-259-6432, cell 256-259-7728). He is an expert at replacing generators - does lots of Hatteras'. I looked at his work before I hired him. He and his helper replaced my genny with a NL12kw in 3 days. They didn't leave a scratch, ding or fingerprint anywhere! They gantry the old out/new one in right through the aft deck, salon, pilothouse, stairs and access hatch in your office floor. Yes, there is a hatch there approx 60"x18", it contains your daily maintenance hatch you referenced. These guys were fair, worked 14 hrs per day, painted the floor before putting in the new genny, etc.
At the time my boat was in KY, he is set up to drive to wherever you are and do the work. I used my davit to move the heavy parts to/from the dock. Good guys, quality work! The labor was about $10k. He is a dealer for many genny brands, NL, Westerbeke, etc.

Bear'
1984 61' MY Strategic Plan

 

[spartonboat1]

When you try to start the genny and it will not "roll-over", have you visually observed and verified that the starter solenoid is fully engaging through its full stroke? It it does not fully engage, then the two points on the end of the solenoid, which act as a relay, will not "make up" and the starter motor will receive no juice, will not operate and bingo, no roll over. My solenoid got a little sticky this spring and I had the same symptom- would not roll over. I applied a shot of WD-40 freed it up enough to fully engage.

 

[Genesis]

Yep.

First things first - when you push the button does ANYTHING happen? If not, does the genset have +12V power? Check that.

If it clicks or if you have +12V but no click, jump the solenoid by hand and see if it engages and rolls over. If nothing happens the solenoid is likely open. Pull the starter and replace the solenoid. If it rolls when you jump it but not off the button, look for a fuse in the starter circuit for the solenoid that is open or a bad connection (e.g. bad switch, etc)

If it clicks but doesn't roll, the points in the solenoid may be bad or it may be stuck and not engaging fully, keeping the points from closing. If it clicks and engages but the starter does not turn, the main windings or brushes in the starter may be bad, or the engine may be locked up.

Put a wrench on the crank pulley and see if you can turn the engine. NOT FAR - just see if its locked up. If you can move it, its not locked up. Assuming you're getting a click and the engine is NOT locked up, the starter itself is bad - either the main windings are open, the brushes are bad, or the solenoid is either not pulling in all the way or its points are dead. Remove and fix it.

If the engine IS locked up, you're screwed.

 

[captddis]

Check that there is 32v to the gen, then does the relay kick in? If so check the brushes for the cranking. [They are the fatter ones] also look for arcing at the brushes. If it is neither there is a good chance the back end going.
Of course check the simple things first like the cranking limiter etc.
Don't look for a starter as there isn't one.

 

[thoward]

First things first.....Is the battery charged? Is the isolator on?

 

[Tawney1]

Thanks guys!

Yep, battery is fully charged. I will check the Isolater, and follow-through with the other suggestions. I will keep you posted!

Paul

 

[MikeP]

"I turned it off to clean the strainer. Then, when I tried to fire it up again. Nothing."

I'll apologize for sounding like a total cynic here but if something used to work, then you did something related to that component, and now it doesn't work, the first diagnosis any Dr or mechanic would make is that the reason it doesn't work is related to something you did...

Is it possible that in your strainer cleaning you moved around and accidentally bumped/disconnected a switch/broke a wire loose from something, anything like that?

 

[krush]

I'd check if it's locked up first...that's the easiest to do! From there jump the solenoid with a jumper cable strait to the starter.

 

[Tawney1]

Mikep,

I thought about that possibility, but in retracing my steps I didn't come close to anything that would affect the operation from a power, etc., standpoint. I didn't touch the generator, its wiring, or the soundshield, etc.

Paul

 

[Brian Degulis]

Hi I'm pretty sure that unit doesn't have a starter it uses a winding in the electrical end to turn it over. If that's the case then solenoids plungers etc are not aplicable. There is a crank reset on the electrical end check that. Check to see it's got 32V getting to it. Remeber there's a battery switch in the stb engine room for the gensets.

If it's turning but not starting check the fuel solonid on the injection pump make sure conections are good and 32V is getting to that when you crank it.

Life expectancy I think at about 6000 your probobly on borrowed time the most common failure on them is the comutator rings in the electrical end and I don't think you can get them any more. But your problem sounds like it's probably something simple.

Replacing it? There should be a larger hatch about 6'x2' it's where the 2x2 hatch you mention is located probably hidden under carpet. From there (for me anyway) it's a tough decision weather to muscle it thru the pilot house galley and saloon. Or cut thru the roof above the hatch that would make removale and replacment a snap with a crane but of course then you got the fibergalss and woodwork and the headliner to deal with. Somewhere down the road I'm going to have to do that to mine and at least right now I'm thinking cut thru the roof. At least then all your work is in one area and both gens can be replaced for about the same effort.

Good luck
Brian