Kohler 5e Low CO Generator Problems

[skolbe]

I have been having problems with my generator for the last couple months. We had a flood, where we couldn't use the boat for a month this year. Prior to that the generator always acted fine. We had run it for about 4 hours right before that and had no issues. Then after the flood I went to start the generator and it ran for a few minutes and died. Open the hatch and notice the error code on the front is LOC - or low coolant. Went to add coolant and it ran fine for a while. Then I got a shut down error again. Saying LOC. So, added coolant and everything ran fine for a bit.

After the next shut down - I changed the impeller and everything ran fine for a while until. I sucked up some tree mulch in the sea strainer and I got the error again. During this time. I noticed the generator puts out some steam out the exhaust. I never noticed it before, but never looked at it too closely. Changed the impeller again. Just in case - this weekend. It ran fine at the dock. Went out to anchor and it shuts down again. I have added coolant a couple of times by removing the cap on top of the generator. Both times it was a little low. Not significant.

I shut off the valve and opened the strainer and everything is fine. So, I opened the valve with the cap off to check water flow. Some water came into the bilge but it wasn't gushing. Is this normal? I don't know what is normal? Is some steam coming off the generator exhaust normal? Is it possible that coolant is leaking somewhere into the engine? Oil levels are fine. I am good with maintenance, but not a mechanic.

The generator had 45 hours put on it last season and 65 this season. It would have more if I could keep it running.

Thanks everyone for your help.

 

[Presentation]

Sorry, I can only help you with one of your questions about water flow.

Take the cap off the air conditioning strainer and open this valve. This will give you a comparison for the water flow for your generator thru hull.

I have done this and I would call it gushing, the water comes out very fast. I have done it to both sides.

We have a generator but we have raw water cooling so I have no coolant. I have never noticed any steam coming off of the exhaust but have not closely looked either.

My guess is your theory is the low water flow is causing the coolant to get too hot and expand and cause loss of coolant.

This is our first year with a generator and I'm very happy we got it. We are at 70 hours.

 

[Stray Cat]

After you sucked up the mulch, you may have debris in the water pick up, or the hose between the seacock and the strainer. Your LOC may be coming from lack of river waterflow through the heat exchanger.

I sucked up some grass once, cleaned the strainer and still had little water flow as you described. I used a garden hose with one of those hose ends that allowed me to clamp the inlet hose from the strainer to it. After back flushing it, it was all good.

 

[skolbe]

Would the low water flow cause some coolant to burn off/evaporate? Also would that lead to some steaming? My strainer cap had a slow water flow. So, that leads me to believe something is caught in there. Put it this was with the cap off and valve open. I would not have worried about the boat sinking too fast.

 

[Stray Cat]

Is the water level consistant in your overflow bottle? Coolant shouldn't evaporate off. If you have a Raytek hand held thromometer, (every boater should have one of these) shoot it at your heat exchanger to check the temperature. Mine runs right at 170 deg F and the exhaust muffler is right at 135 deg F

I don't remember seeing a lot of steam at the through hull outlet, maybe a puff once in awhile. I do remember that under a no flow water condition, the genny exhaust tone was slightly louder than normal.

 

[William Miller]

Not the same boat, but I think I have the same generator. (5ECD)
It's a later 2006 model that I took delivery late march 2007.

I only have about 25 hours on the generator because we use it mostly as a day boat.
Mine has closed cooling and I have had to add some coolant into the tiny overflow tank more often then I would expect. I thought it might have overflowed after getting hot, but I think its going somewhere else.


Last fall just before winterizing the boat, the siphon break started spewing water. This is a 1/2" or so rubber hose that goes up to a plastic fitting up above the highest point of the generator.

Called the dealer and they said Kohler experienced some problems with the Catalyst and there was a recall. Over the winter, they replaced the Exhaust manifold/ catalyst and the syphon break.

I still loose a little (pink/orange) coolant which is something I need to look into.
I don't know much about the details about the recall and I'd like to learn more about the Kohler warrantee. (I don't have any paperwork with me at home.) I don't know if the warrantee is longer than 1 year or if they would cover something mentioned before the 1 year that has continued to be a problem. My coolant loss issue may be related to the Catalyst if the generator somehow has a partially split gasket somewhere. I don't see any pink stuff in the tray or in the bilge.

Hope this helps! I also joinde the thread to learn anything I can about the generator.


BTW, Is your generator battery connected to the charger/converter?

 

[skolbe]

It has stayed normal in the overflow bottle. It's once the genny cools off - I have added a little coolant. I am thinking there must be a restriction at the through hull or the line. because - I remember pulling the cap off an engine through hull strainer and opening the valve - I had a clogged through hull and once it broke loose. Water was gushing in pretty fast. Enough to where you want to close the valve quickly. Whereas this stainer - for the generator would just kinda spill over the sides a little. My generator is on the starboard side battery bank. I read the warranty last night. It is 2 years, mileage parts & labor - years 3 through 5 there is a $100 deductible. It has to be an authorized Kohler repair center. Not sure if Marine Max is a certified warranty dealer.

 

[William Miller]

I forgot to ask:
Do you have the strainers with the screw on caps?
If so, I got a spare cap and with a few fittings have a garden hose adapter. I use this to flush and winterize the genny, A/C and I also have raw water because the AJ has a bait tank and raw water washdown.

I also use silicone grease on the threads and O-ring on those caps to make them easier to get on and off.

 

[Stray Cat]

Whereas this stainer - for the generator would just kinda spill over the sides a little.

Not normal, even with a 3/4 id hose, it should gush in pretty quick. Back flush the water inlet to be certain it is clear.

 

[skolbe]

Thanks everyone. That will be my next step.

 

[summertime]

I just finished putting a new impella in my 5E Kohler. I started the generator and let it run for about a minute, but still no water. Is this enough time? I don't want to burn up another impella.

 

[Big Billy]

One thing to realize to with these 5E and 5ECD is that the thermostat inside has a double baffle on it, one is normal like most cars but at the bottom it has a second baffle which creates a blockage and keeps coolant from getting all the way around. The only way to really fill the genny is to take the cap off and across the top on the back side of the exchanger housing is a 1/4" plug you have to take out in order to completely fill and purge the air. I pour it in the radiator cap and wait until it comes out the plug, put the plug back in, radiator cap on, then you're full. As it runs coolant goes in and out of the over flow bottle, after a while when all the nooks and crannies are full of coolant, you should stop loosing it. If you continue to after a few runs, the most likely suspect is the heat exchanger. After 35 hours of run time, the zinc anode is probably used up, so if you're like me and don't replace it that often, your exchanger may pay the price. I know they changed the way the raw water exhausts from the engine, from just dumping it in the exhaust pipe to exhausting it through multiple holes around the exhause manifold, and after a while they are blocking up from crystalized salt water, so that may be an issue to consider. If you were following my thread on the 5E, a lot of folks were finding their dedicated battery for the genny had depleted and that was causing issues, so be sure it's fully charged. There are three shutoff for the gen, low oil pressure, low coolant level, and high coolant temperature. Backflushing the line to the strainer is a good tip, some things don't make it to the strainer, my in line between the hull and strainer had a good supply of barnacles in it. As for steam, you don't want steam......

Bill

 

[skolbe]

I always have soap on the impeller - so, I can tell once the water has pulled past the pump - plus it makes it easier to install the impeller. The water starts flowing within a few seconds - you will see suds coming out of the exhaust.

 

[Al Gross]

You definitely do NOT want steam coming out from the generator. Also, you should essentially get a small gush of water when you open the through hull valve without the cover on (e.g., just bubbling over the top lip). Sounds like one problem is lack of water flow--you MAY have to go or reach under boat to see if through hull valve clogged from outside.

My experience is that even a new impeller cannot draw sufficient water if through hull is clogged. I wholeheartedly agree that backflushing system should also help.

If you've done all suggested herein and below, then I'm not sure what is wrong. Sorry

 

[firecadet613]

What would steam coming from the gen exhaust indicate? Not enough water flow/bad impeller?