Intermittent High Temp Alarm - 2000 150hp Optimax

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webre

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Aloha. Serial No. on this engine is 0T148359.

The symptom is that after the engine is warm, slowing to idle will often cause the alarm. Sometimes I have to restart because the safety engages and engine will only idle, other times I can hit the throttle. The alarm rarely goes off at cruising rpm, 4600-5200, but it has once or twice. I do not have a temp guage. 18.5' bass boat has the 4-light instrument cluster, an rpm and water pressure gauges.

Have been getting this high temp alarm for awhile, new impellers don't seem to make any difference. I installed one and the shop I took it to installed one. Another shop replaced the alarm module (there was no alarm when turning on key, they fixed that, but I still got the high temp alarm).

Water pressure is much lower at idle, barely registers on gauge. At 4800 rpm, the pressure is near 15 psi. Water is circulating at idle and at higher rpm, there is always steady/strong stream at the outlet.

Today I pulled the 2 thermostats, they look OK but I'll replace. I want to check out/replace the poppet and assembly, but there's a lot of stuff in the way. Do you normally cut and splice the wires for the trim switch? It's too big to fit back through the cowl opening. What else do I need to watch out for in terms of the electrical components on that side?

I've read the posts regarding the poppett, I should be ok replacing it. What else can I check? Thanks.
 

Texasmark

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Re: Intermittent High Temp Alarm - 2000 150hp Optimax

You have a lot of inputs on this thread. It's been awhile since I have been into a 150+ hp but if like most midrange to higher, you have a stat for low speed operation to meet the EPA (whoopie) mandates and then you have a bypass called a popoff for higher rpm's. My manual talks about 2500 rpm's for the cross over point. I have experienced a stuck shut stat with the whistle blowing and merely getting on plane and getting the water pressure coming in and the rpm's up and the alarm goes off and stays off till I got back below 2500.

Stats can be checked on the stove in a pot of water and a candy thermometer (need that to get the range you need). The pellets are stamped 143F meaning that is where they start opening and by 153 or so they are fully open. You can see that happen on your wife/girlfriend's/whatever's range top. The warning sensor closes at 193F and shorts out the alarm causing it to sound.

Popit valve is a large valve that bypasses the stat for speeds above 2500 and allow more water thru the engine and by the time you are at that rpm, you don't need to worry about cold ignition and all the stuff that stats are there to protect you from....course Merc was making and shipping engines for like 50 years before they added a stat to satisfy the tree huggers.....thunderbolt ignition was the fool proof alternative.

Pooped.

More later,
Mark
 

webre

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May 25, 2012
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Re: Intermittent High Temp Alarm - 2000 150hp Optimax

Thanks. I have service and troubleshooting manuals on the way. If I understand your post, I should focus on the low rpm cooling system, which rules out the poppett for now. Hey, it's hot where I live and I don't run this boat a lot, so the impeller is probably due again, but as I said, even when impeller is new this still happens 'most' of the time.

The temp sensor is located on the top-right side, at No. 1 cylinder. There is a hole for a temp sensor on top-left side, at No. 2 cylinder, but no sensor is installed there. Is that typical? I'll probably replace the sensor too, while I'm at it.

By the way, I have another issue with this motor recently, which is that it doesn't always fire on all cylinders. Last weekend could only get about 4000 rpm, but I'll post separate thread on that problem if need help. The temp issue has been happening since long before this low power problem though, so I don't think they're connected. Found fouled plug and corroded plug wires.
 
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