Kohler 5ECD smoke from Exhaust and gas smell

Crushin It

Crushin It

Well-Known Member
GOLD Sponsor
Oct 10, 2006
1,716
Safe Harbor Marina Kent Island, MD
Boat Info
2006 44 DA
QSC 8.3s
Engines
Cummins QSC 8.3s 500HO
History - About 200 hours on Generator. I run it at every outing and never an issue. Yesterday I see what appears to be smoke from exhaust and slight gas smell. Generator was running perfect otherwise. I haven't had a chance to visually look at yet as it was dark when we got in last night. Any ideas???

Thanks - Mark
 
White smoke? Sounds like the choke may be sticking. It has an automatic choke that "searches" once the genny is started and normalizes after a 10-15 seconds. Also, when was the last time you changed the plugs? These Kohler generators eat plugs. Make sure you use the exact spec NGK plug.
 
Start with changing spark plugs. As has been mentioned, Kohlers do eat these things up. Not sure if we have the same exact model but on mine: NGK BPR4ES, and the local Autozone usually has in stock. Gap .026.
 
Plugs are at least two years old that I know of. Possibly more. I have only owned boat for two years. The NGK BPR4ES is the plug required. I will try new ones tomorrow and check choke.. Thanks for the suggestions...
 
villain style said:
Well could not find the NGK plugs - found AC autolite equivalents. Should I install or wait for NGK's?
Click to expand...

Yes, you want the NGK plugs. They are available at West Marine. I have a couple I'll sell you with an impeller, oil filter and anode if you are interested.
 
Heres the update - On a cold engine I checked the coolant level from the cap and it was full. I Installed the two NGK plugs today that took about 2 minutes. Did not need to remove any housing from generator to install them. The old rear plug (Champions) appeared fouled. Started the generator up. Smoke (or the same appearance as hot exhaust over cool water becuase it did dissipate) was still coming out exhaust after about 5 mins runs time. The exhaust/water felt hot and no noticeable smell of gas or coolant in exhaust. Then genny shut down with a HE code. The overflow bottle completely filled up with coolant. Let it sit for about 10 minutes. Started right back up and then shut down after 1 minute with a UU code.. Genny only has 80 hours on it. It appeared to be overheating if I had to guess. I did read someone else's post that said the exhaust elbow may be clogged and that there was a recall for a new exhaust elbow. Anyways - I shut down and here I am.....aggravated.
 
Last edited:
Have now read that if the genny shuts down under load it could throw a UU code. Thats what happened and I suspect that is why the code. I will shut batteries off and reset genny and see what happens next. I may just get the HE code. I hope I get no codes. I should have checked water strainer and basket for obstructions but didn't. Will get to that tomorrow.
 
While you're checking the flow from the seacock you might as well change the impeller and the anode too, both 10 minute jobs
 
When did you change the impeller and were all the vanes intac? If there were any missing, did you find them all?

The anode is behind the water inlet to the cooler, the wrench flat is brass. Hold a cut in half water bottle under it as you remove it to catch the salt water.
 
I'm still diagnosing overheat issue. Yesterday it started right up and I was watching it run under a load for about 8-10 minutes. Coolant slowly filled the overflow bottle in that time. The coolant reach mid way between the marks on the bottle at which time I just shut it down. I assumed it would have gone all the way to the top of bottle. I'm reading a lot about an air pocket that could be the issue for over heating... What would cause an air pocket?
 
Read you manual for gen, there is a bleed screw on top that will remove the air pocket, also how is your water flow?
 
The flow goes in surges, and by looking at that photo, your in between a surge or you got inadequate flow. Impeller chunks can get caught in the line to the strainer as well. Blow through all your lines and into the exchanger as well. Or maybe you got it so hot you blew a head gasket, look for air pressure in the overflow bottle
 
There is also replaceable plastic gear behind the impeller that should be checked also and have your heat exchanger pressure test And cleaned
 
You must log in or register to reply here.

Forum statistics

Threads
113,297
Messages
1,430,146
Members
61,160
Latest member
McLeod Evaline
Back
Top