kolher 6.5 genny

if you search the web you will find the service manual you need to use the correct leads and proceedure. the manual calls for 50 volts ac my kholer dealer said you can use 120 but I followed manual to get 50 volt I took a light bulb and a dimmer switch and adjusted the switch to it registered 50 v then flashed the field you hear a hum as you flash the field. did you just reassemble the generator why did you lose the field?
 
Not sure that I lost the field, the gen stops running when the start switch is released. the first thing the manual states in the troubling shooting section is the flash the field, then look into sensors for being faulty.

What about this cap I see during web searches, where is it? I know its function is the excite the field,
 
is doubtfull its field the service manual has a flow diagram of what to check in what order most likley cause is either bad capacitor or stator is shorted (what happened to mine) sytematically check all thing a local electric motor shop will need to check continuity of stator as cheap liitle ohm meters not reliable in that ohm range they rebiult minefor a few hundred dollars when you reassemble the you will need to reflash the armature field
 
I dont have the manual in front of me but i recall when holding down the start switch if the generator produces 3 volts or so the field is intact and does not need to be flashed . This is a brushless generator it
produces a field in one of the windings send this voltage to ecxitation capacitor which induce voltage in another winding and then you get your expected output.
 
Where would this capacitor be located, is it on the controller board?
 
its in between stator and cotroler box believe leads 55 56 attached to it remenber capacitors can store large voltages
 
question, how do i rule out the sensors, are they normally open or close?
 
I think open do you have any voltage output bwhen you hold down start switch what voltage can yo measure on leads 55 56 when you hold down switch if you have from 2-5 volts yuoh have a field then you need to check continuity test stator leeds page 7_5 on manual must disconnect leeds from controller board to test there ale also diodes on rotor that can go that need to be tested problem is need to remove stator to test sometimes a weak field can be stregthemn by trying to start generator with a load on it turn on few light bulbs while staring it might help but if you dont have voltage while tring to start it the field capacitor stator or rotor not boards or shutdown switches
 
I have read that there is 1 wire which can be removed and all the safety sensors will be by-passed, anyone know which one it is??
 
only 2 sensors heat on ehaust manifold unlikley when cold oil pressuresxt bypassed when holding down starter switch. Ifyou hold down starter then engine will run but stop when switch is released do you have A.C. output If you have 120 V then it can be sensor board relay if yo only have 5 volts or less need to test items i mentioned before . You need to check ouput voltage of generator
 
Eric,

Installed new starter today, and check for AC voltage when running (still have to hold start switch)I am getting 2.5 VAC at an outlet near the Genny. What do I do next
 
You may have a bad capacitor bad stator or a bad rotor board.Those genny's are very nice.But when they come with a problem like that will be a dor de cabeca.I work with them I know that.I'm a kohler service center.
 
same problem as mine is not the sensors it is either a bad capacitor cheap easy fix (remember capacitor hold large stored elec charge ) if you have capacitor tester can test or just replace 10 $ part i got one from Grainger or else you need to test stator leads there is chart in manual if u dont have i will tell you the order or you can look up
basically some leads have continuity others do not and can be shorted to ground you will need to disconnect all leads from the control box before the test my genny it was a bad stator to really test stator properly it needs to be removed and tested with a megaohm meter but you will get an idea with a cheap meter if there is a short last possible thing that will give a 2.5 volt reading s the blown diode on rotor can test that again only problem must remove stator to get two then unsolder leads to test
i would first replace capacitor see if it works cheap part and it may be problem then test leads with stator in place then you will need to remove stator to test leads and rotor board a motor shop can rewind stator i paid 350 for mine

since you are producing 2.5 volts you have a field (hope you try starting while under a load) the generator relays wont allow generator to run once the starter switch is released unless it see 120 V hope that helps keep us posted
 
could used a part number for the Capacitor, would you know it off hand?
 
Thanks guys, Picked up the cap at Grainger on my way to work, it the event that it does not work, should I still consider the LOP switch? If so how should it be bypassed, there are 2 post G and WK, do I removed all wires, do I connect all 3,
 
measure the leads on the stator you can do that wihout removing it to get an idea both me and boatcomfort are telling you it capacitor rotor board or stator if it was the low oil pressure switch you would have seen 120 v when cranking
 
Well the new capacitor did not help, still only seeing 2 volts AC at outlet, how does the new cap get charged? After running the motor should I be able to measure voltage across the cap? I also check for voltage at the cap while running got nothing.

I measured the resistance across 55/66 got 2.4 ohms.

What about the voltage regulator?
 
you must due continuity test on stator leads next dont look for other reasons what happens one field in stator induces a field in other leads two of the fields are combined to produce 120 another field produces 12 v for battery if there is a short in the windings no output that why you must disconnect all leads and test continuity
 
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