Kohler Gen Sets Continuous Problems

[CarpeDiem]

I am on my second Kohler 5.E generator on a 25ft Doral 250SE.<br /><br />The 1st generator was a 1999, which had numerous issues and was eventually replaced in January of 2001. This second generator has followed the same path. <br /><br />Since its installation I have had numerous issues ranging from bad sensors, to having to replace the carburetor and starter.<br /><br />After numerous repairs the repair shop the repair shop stated that it appeared that the generator was taking in water. They stated the cause was due to improper installation. <br /><br />Although the installation was done by a Kohler Certified shop and Tech, Kohler refused to <br />cover the repairs under warranty. Wanting the problem resolved, I ate the cost of replacing the Kohler Factory fuel filter, the addition of a second heavy duty filter and Addition of a siphon break.<br /><br />The generator has again taken in water. Water was found in the oil and in the cylinders. <br /><br />I have spoke with several others who have experienced similar issue with the Kohler 5.E generator. Is this a common problem with this generator?

 

[Capt Ken]

Re: Kohler Gen Sets Continuous Problems

This question would probably get more response in the engine section due to it being an engine problem. We dropped the Kohler line several years back due to lack of support from Kohler to the dealers and went to Westerbeke. I know of no problems that was common to that genset. If the engine is using an aqua-lift muffler with a siphon break on the water line along with a flat thru hull instead of a scoop, there should be no reason for this unit to take on water. Sounds like an installation problem still exists and hasn't been solved.

 

[CarpeDiem]

Re: Kohler Gen Sets Continuous Problems

Thanks Capt Ken, <br /><br />Yes, I had it in the engine section but that was closed saying responses should be posted here. <br /><br />The engine is using an aqua-lift muffler and <br />flat thru hull not a scoop. <br /><br />Initially it did not have a siphon break<br />but I had one added, but I believe it is above the water line, Could this be pasrt of the problem ?

 

[Capt Ken]

Re: Kohler Gen Sets Continuous Problems

Only time the siphon break comes into action is when water leaks past the water pump impeller. Normally if the pump is in good shape, this won't happen. Now if the genset has a hard time starting, or if you have to spin the engine for more than a couple of minutes, the pump will fill the muffler system with water and back it up into the engine. I see this alot on engines that won't start quick enough to blow the water out the exhaust. Also the exhaust hose leading from the muffler to the thru hull should rise above the water line before exiting out the side of the boat. I usually like to get a upside down U just before it exits the thru hull. This will keep waves from forcing themselves back down the exhaust hose. They will tell you these mufflers will keep water from coming back up the exhaust but not if the exhaust valve and intake valve is partially open. There's a booger there, just got to find it. You almost worried me there when I paid attention to your name. I just replace a Kohler with a Westerbeke last month in a boat by that name. Except for it was a Luhrs.

 

[CarpeDiem]

Re: Kohler Gen Sets Continuous Problems

Thanks again Capt Ken,<br /><br />Yes the exhaust hose goes straight up from the thru hull forming an upside down U, The drops down has a loop forming a Circle then to the Genset. <br /><br />The genset is not hard starting, when it works, <br />There have been more repair hours than running hours logged on it. <br /><br />They have brought this up and stated thet I may have over cranked it. I do not believe this could not be the cause, It started and ran fine under load for about 45 minutes, less than 24 hours later it would not crank, The boat had never left the slip. They tried to claim that the engine won't crank because it was run with water in it an froze up. The engine is not Frozen. The engine won't crank because the cylinders have water, water does not compress. I would think that had the engine been run with water all the oil through out the engine would have water mixed in it and be white and sluggie but this is not the case. <br /><br />Just worried I am going to spend a lot of money getting it fixed just to reoccur. <br /><br />Kohler is now claiming it must be an installation issue. Other than the addition of the siphon break, I am told by the shop (Not the Place that installed it) the installation is to Kohler Specs. <br /><br />It was installed, and worked on only by Kohler Certified Shops and Techs. If truly an installation Kohler need to back up the shops and techs they certify. <br /><br />Thanks again

 

[Capt Ken]

Re: Kohler Gen Sets Continuous Problems

If everything you describe is correct, then the unit is installed correctly. The problem is probably in the genset. One of the reasons we dropped the line in the late 90s was they were having some problems with the small gas units and not telling the dealers about it. (I had to find out from my Westerbeke rep) After being threatened by several customers of lawsuits due to their units not being operational and the Kohler rep telling me to let them sue, I decided I didn't need to be in that picture anymore.