pyro
Active Member
- Dec 4, 2018
- 287
- Boat Info
- 2008 Sundancer 290
- Engines
- Twin 5.0L MPI Bravo III
Kohler 5ecd
I purchased a boat with known bad generator Kohler 5ECD generator. These are the fuel injected generators and many people seem to have similar issues to what I am facing. Hoping to share some of what I learned.
Problem description is the generator would not start intermittently. Some days it would start but would die shortly after. It would throw errors EC62, UU and UF. This year after dewinterization the engine barely runs.
We determined the issue is likely fuel related. The fuel injector was replaced 2 years ago on this unit and has less than 4 hours of runtime since that service. We removed injector, tested, and discovered the injector valve was sticking. Sometimes tapping on it would release it, other times you had to wait. We are going to send it off to get cleaned. Kohler part number for this GM62619 and is somewhere around $130. The injector is actually a Siemens Deka injector with part number 39-032. Also labeled on the unit is 8032F06572 and 07/315 15. There is no information on the internet for this injector. I called a local injector cleaning company, they barely wanted to talk. I emailed another place online, no response. I emailed InjectorRx and to my surprise the owner called me and went out of his way to look up the specs for this injector. I am sending the injector to InjectorRx. I think I have found an equivalent Bosch injector but waiting for confirmation from the guy at InjectorRX for confirmation. I can't say enough about how helpful this guy was - send your injectors to InjectorRx!
Plugging up an injector so quickly points to something else wrong. Generator is out of the boat and operating from an external fuel tank. We would prime the fuel system and noticed the first bit of return fuel from the schrader valve near fuel injector was initially a noticably darker color. After a few seconds it would clear up as it fresh gas from the tank made it through the entire system. This has been repeatable for 3 times letting it sit for more than 3 days. The discoloration is coming from either the high pressure water cooled pump, pick up pump or the fuel line.
The fuel on the right is the first fuel out of the pump after being in there for about 4 days. The fuel on the left is the new gas from the external tank and collected AFTER the stuff on the right. It does not seperate after leaving it overnight. I'm not sure why its discolored, but I suspect its clogging the injector, and I suspect I'm not the only one with this issue.
Next we are going to measure the fuel pressure from the high pressure fuel pump - although no one knows what it's supposed to be. Then attempt to check if fuel discoloration is from high pressure or low pressure pump. We may try a close loop flush of Seafoam or other cleaner to see if the internals can be cleaned up. Or we may attempt to open the top up to inspect insides. Not sure if this is servicable so expecting to replace at that point. I suspect the high pressure fuel pump is a standard off the shelf fuel pump with a custom Kohler assembly to water cool the pump. This thing is very expensive ~$550, but no alternatives found so far.
If I replace the high pressure pump I will probably replace the low pressure pump to guarantee an entire new fuel system. I was able to find a cheaper source for the low pressure pickup pump. The Kohler part number is 278490 and runs about $110. It is a Facet Pump part number 40178 that creates 2-3.5 psi. You can find this for about $60, only difference is you will have to splice the connector onto the new Facet Pump. The part number is actually stamped on the bottom as documented here:
https://www.pegasusautoracing.com/document.asp?DocID=TECH00023
Cross reference: http://www.facet-purolator.com/wp-content/uploads/pdfs/2018 Industrial catalog.pdf
Will post updates.
Problem description is the generator would not start intermittently. Some days it would start but would die shortly after. It would throw errors EC62, UU and UF. This year after dewinterization the engine barely runs.
We determined the issue is likely fuel related. The fuel injector was replaced 2 years ago on this unit and has less than 4 hours of runtime since that service. We removed injector, tested, and discovered the injector valve was sticking. Sometimes tapping on it would release it, other times you had to wait. We are going to send it off to get cleaned. Kohler part number for this GM62619 and is somewhere around $130. The injector is actually a Siemens Deka injector with part number 39-032. Also labeled on the unit is 8032F06572 and 07/315 15. There is no information on the internet for this injector. I called a local injector cleaning company, they barely wanted to talk. I emailed another place online, no response. I emailed InjectorRx and to my surprise the owner called me and went out of his way to look up the specs for this injector. I am sending the injector to InjectorRx. I think I have found an equivalent Bosch injector but waiting for confirmation from the guy at InjectorRX for confirmation. I can't say enough about how helpful this guy was - send your injectors to InjectorRx!
Plugging up an injector so quickly points to something else wrong. Generator is out of the boat and operating from an external fuel tank. We would prime the fuel system and noticed the first bit of return fuel from the schrader valve near fuel injector was initially a noticably darker color. After a few seconds it would clear up as it fresh gas from the tank made it through the entire system. This has been repeatable for 3 times letting it sit for more than 3 days. The discoloration is coming from either the high pressure water cooled pump, pick up pump or the fuel line.
The fuel on the right is the first fuel out of the pump after being in there for about 4 days. The fuel on the left is the new gas from the external tank and collected AFTER the stuff on the right. It does not seperate after leaving it overnight. I'm not sure why its discolored, but I suspect its clogging the injector, and I suspect I'm not the only one with this issue.
Next we are going to measure the fuel pressure from the high pressure fuel pump - although no one knows what it's supposed to be. Then attempt to check if fuel discoloration is from high pressure or low pressure pump. We may try a close loop flush of Seafoam or other cleaner to see if the internals can be cleaned up. Or we may attempt to open the top up to inspect insides. Not sure if this is servicable so expecting to replace at that point. I suspect the high pressure fuel pump is a standard off the shelf fuel pump with a custom Kohler assembly to water cool the pump. This thing is very expensive ~$550, but no alternatives found so far.
If I replace the high pressure pump I will probably replace the low pressure pump to guarantee an entire new fuel system. I was able to find a cheaper source for the low pressure pickup pump. The Kohler part number is 278490 and runs about $110. It is a Facet Pump part number 40178 that creates 2-3.5 psi. You can find this for about $60, only difference is you will have to splice the connector onto the new Facet Pump. The part number is actually stamped on the bottom as documented here:
https://www.pegasusautoracing.com/document.asp?DocID=TECH00023
Cross reference: http://www.facet-purolator.com/wp-content/uploads/pdfs/2018 Industrial catalog.pdf
Will post updates.