Kohler 5E generator help

Discussion in 'General Discussion' started by mnm99, Jul 10, 2019.

  1. mnm99

    mnm99 Well-Known Member

    Oct 2, 2015
    Long Island
    2004 340 SeaRay Sundancer
    Twin 8.1 Merc
    This is for a friend, but I'm helping him out. The generator is overheating. So far I took off the exchanger and cleaned it, Verified the thermostat was opening at the correct temp, Replaced the raw water impeller, and made sure the fluids were good. Here's what it's doing. It pumps raw water good. The exchanger is cool, but the manifold is HOT. It shuts down after 3 min. I'm thinking it's either a bubble or a bad fresh water pump. I never replaced a fresh water pump before though. How can I tell if it's working correctly. The manifold doesn't have that little bleed plug on top either. Ideas?
     
  2. Little Ducky

    Little Ducky Well-Known Member

    Jun 5, 2017
    Dickson, TN / Chattanooga, TN
    1998 290 Sundancer
    Twin EFI 5.0L w/Alphas
    Kohler 4kW
    Make, Model and Year?

    Is it boiling out the coolant?
     
  3. mnm99

    mnm99 Well-Known Member

    Oct 2, 2015
    Long Island
    2004 340 SeaRay Sundancer
    Twin 8.1 Merc
    like in the title it's a Kohler 5E., 2001. Yes pretty much it boils over once it heats up and then shuts off
     
  4. Jeremygavin

    Jeremygavin Well-Known Member SILVER Sponsor

    Mar 6, 2012
    Cape Cod, MA
    2011 520 Sedan Bridge
    2016 Sea Ray 19 SPX OB
    2019 Walker Bay Generation 340
    Cummins QSM11s
    Mercury 150 Fourstroke
    Honda 40hp
    They tend to be hard to bleed the air out of the coolant. I had a 5e on my 340da. There is a plug in the top of the heat exchanger that you need to pull to let the air out. Do this while running it. I haven’t done it in about 6 years so I maybe missing a step here but I got the info from CSR so try a search for it to get a more complete procedure.
     
  5. Korkie

    Korkie Active Member SILVER Sponsor

    474
    Feb 2, 2016
    Leonardtown, MD Potomac River / Chesapeake Bay
    340 Sundancer 2006, Garmin 7612, xHD Radome
    Merc 496 Mags
    Bravo III Drives
    Hey Jeremy - I have changed out the coolant pump on mine. Wasn't too bad. Took about 3 hours total. It does have a small hole in it that will start leaking if the shaft seals go bad. That is what caused me to change mine. Not sure on how to tell if it is actually circulating the coolant.
    Assume the raw water impeller was in tact?
     
  6. mnm99

    mnm99 Well-Known Member

    Oct 2, 2015
    Long Island
    2004 340 SeaRay Sundancer
    Twin 8.1 Merc
    Yea I did a bunch of reading. My friends gen didn't have the bleed, so I made one. I noticed antifreeze come out somewhere , but only when it overheated. I'm getting 2 new O-rings and stat for the exchanger. Once that's all together, I'll give it a try.
    thumbnail (25).jpg thumbnail (26).jpg thumbnail (24).jpg
     
  7. mnm99

    mnm99 Well-Known Member

    Oct 2, 2015
    Long Island
    2004 340 SeaRay Sundancer
    Twin 8.1 Merc
    Fixed...Air lock. Once the plug was tapped I was able to add a bunch more antifreeze. No more overheat.
     
    susanandlance and carterchapman like this.
  8. Jeremygavin

    Jeremygavin Well-Known Member SILVER Sponsor

    Mar 6, 2012
    Cape Cod, MA
    2011 520 Sedan Bridge
    2016 Sea Ray 19 SPX OB
    2019 Walker Bay Generation 340
    Cummins QSM11s
    Mercury 150 Fourstroke
    Honda 40hp
    That’s great, there was some work involved but easy enough to add the plug. Without knowing it is an issue with that that would be tough to diagnose.
     
    susanandlance likes this.
  9. KevinC

    KevinC Well-Known Member

    Feb 25, 2011
    Long Island, NY
    2004 340 Sundancer
    1988 Proline Center Console - 90hp Mariner/Mercury
    1969 Boston Whaler
    Twin 8.1 V-drives
    Never would have seen that problem. Is that just a filler plug or does it have a bleeder in it?

    -Kevin
     
  10. susanandlance

    susanandlance Well-Known Member PLATINUM Sponsor

    Feb 10, 2011
    Florida
    2007 Sea Ray 36 Sedan Bridge
    8.1 mercruisers
    Excellent!!!
     
  11. susanandlance

    susanandlance Well-Known Member PLATINUM Sponsor

    Feb 10, 2011
    Florida
    2007 Sea Ray 36 Sedan Bridge
    8.1 mercruisers
    Looks like a standard transom drain plug from photos
     
  12. mnm99

    mnm99 Well-Known Member

    Oct 2, 2015
    Long Island
    2004 340 SeaRay Sundancer
    Twin 8.1 Merc
    No, I left the plug in then filled to the top of the rad cap. I then pulled the plug out and was able to fill like another 16oz bottle and then it gushed out. I plugged it up, closed the cap and that fixed it. Crazy right! I looked on my gen and it has that plug from the factory. I guess they learned from 2001 to 2004.
     
    carterchapman likes this.
  13. mnm99

    mnm99 Well-Known Member

    Oct 2, 2015
    Long Island
    2004 340 SeaRay Sundancer
    Twin 8.1 Merc
    1/8" brass npt plug.
     
    susanandlance likes this.

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