Really hoping for some answers... We...

[Admiral_Purrl]

Really hoping for some answers...

We have a 2014 330DA with the Kohler 5EKD-Low CO generator and have put too much $ into it in repairs. We have had many "recalls/service bulletins" and have had each taken care of - or at least we were told they had been done.

Our latest issue is that it appears to be running hot but we have no idea what the optimal operating temperature is. Not in the manual. All we find is something that says:

Minimum Load Requirement: 30% load

Ideal Load Requirement: 70% or more load

What does that even mean?

We have been told we may have an "air gap," so... have manual says to remove the screw on the heat exchanger and the fill cap, add coolant in the coolant fill area, close both, run gen for no more than 10 seconds. We tried this, and we still run around 212-217° depending on load. Lowest being just battery charger and outlets... highest using built in Electric Grill.

I have also seen posts where it instructs pouring additional coolant in the valve on the heat exchanger. Manual does not mention this. If we did that would our results maybe be different?

Also, the marina mechanics seem to think the fill cap is a great place to step on while entering our engine compartment. My husband thought they had damaged the cap, so I got part number from Manual and ordered new cap. The manual says should be 14 PSI, what we received had the correct part number but is 13 PSI. Could that make any difference? I can't find a 14 psi anywhere online or at auto parts store.

We have kept our usage to minimum need somewhere between 30-60 minutes, with no shutdown issues.

Does anyone have this gem of a unit and could please give us some feedback/suggestions as to whether is is normal and if not what solutions we could try. This unit has not worked more than it has worked.

PS 528 hrs, but we think at least 200 of that is the mechanic running it for "hours" after repairing saying it was fixed.

That you in advance!!

[wingless]

According to the service manual, linked document, page 31, the maximum coolant temperature is 210°F.

According to that manual if temperature too high, check for low coolant level and check for insufficient raw water.

In an overheating condition or a low coolant problem also checking for compression leak to coolant doesn't hurt. (Standardized engine testing)

The 13 psi versus 14 psi radiator cap is a non-issue. That sets the overheat boiling temperature for the antifreeze, with a minor difference between the two.

The 30% and the 70% load means the electrical load. For this 5kW generator the 30% load is 1.5kW of electrical load and the 70% load is 3.5kW.

https://www.atlantismarine.co.uk/Images/User//File/tp6593.pdf

[wingless]

According to the linked specification sheet, the raw water circuit pumps 6 gpm, for US 60Hz operation.

Checking to see if it overfills a standard 5 gallon bucket in under a minute is an "easy" test for raw water flow.


https://turtle-marine.com/web_imgs/pdf/G2128%205EKD.pdf

[Admiral_Purrl]

WOW! Thank you. We've been looking at the Operation Manual. Pretty sure coolant level is full, the overflow bottle always fills when we use it.

So when you say fill a standard 5 gallon bucket... do you mean the discharge water coming out of the hull?

[wingless]

Yes, that previously linked data sheet shows it should pump 6 gpm, so that discharge water should fill a 5 gallon bucket in under a minute.

Here is the parts list. I was unable to find a bleed screw for the coolant. Prior experience with other engines is that when the coolant must be manually burped, then the engine has a bleed screw to let out the air. If there is a coolant bleed screw, then use that to let out the air.

https://www.atlantismarine.co.uk/Images/User//File/tp6594.pdf

[Vinster]

Have you run barnacle buster thru the raw water section of the gen? ( 5 gal bucket, small bilge pump, hoses, use sacrafical zinc, run for 1 hour) Crud build up on inside of the fuel cooler module will reduce flow and cause the fuel that's speed thru this module to heat up vs. Cool down causing the gen to stop at various times. Connect the barnacle buster "kit" to the out port of the gen pump and at the exit of the heat exchanger to circulate the barnacle buster.