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Kohler 12 RES Installation


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  #11  
Old 11-17-2018, 10:53:04 AM
zaphod zaphod is offline
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Default Re: Kohler 12 RES Installation

so it's the other way around: Winco is high voltage and Kohler is low. Anyway throwing a grand at it worked for this phase. Now to attack the speed sensor.

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so it's the other way around: Winco is high voltage and Kohler is low. Anyway throwing a grand at it worked for this phase. Now to attack the speed sensor.
Oh yeah, he had to put in a 120V line to power the on board battery charger; the WINCO unit had it built in the ATS.
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  #12  
Old 11-17-2018, 07:16:45 PM
Mark Dieckmann Mark Dieckmann is offline
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Default Re: Kohler 12 RES Installation

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Originally Posted by zaphod View Post
so it's the other way around: Winco is high voltage and Kohler is low. Anyway throwing a grand at it worked for this phase. Now to attack the speed sensor.


Oh yeah, he had to put in a 120V line to power the on board battery charger; the WINCO unit had it built in the ATS.
That makes sense.
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  #13  
Old 11-19-2018, 04:03:12 PM
zaphod zaphod is offline
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Default Re: Kohler 12 RES Installation

so I have a bad speed sensor, the gen defaults to OS immediately on startup. I bought the new sensor, and learned the original is located under the unit. I cut away a bit of the plastic fan shroud and located the flywheel next to the inspection port and mounted the new sensor to the back cover. I get resistance but no signal voltage. I'm using a 0.48 paper shim (installation says to shim between 0.31 and 0.71 ") any ideas? Sensor has resistance, just no signal on cranking. Shouldn't it generate around 3.5 volts AC?
Cheers,
Zaphod
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  #14  
Old 11-19-2018, 06:32:26 PM
zaphod zaphod is offline
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Default Re: Kohler 12 RES Installation

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Originally Posted by zaphod View Post
so I have a bad speed sensor, the gen defaults to OS immediately on startup. I bought the new sensor, and learned the original is located under the unit. I cut away a bit of the plastic fan shroud and located the flywheel next to the inspection port and mounted the new sensor to the back cover. I get resistance but no signal voltage. I'm using a 0.48 paper shim (installation says to shim between 0.31 and 0.71 ") any ideas? Sensor has resistance, just no signal on cranking. Shouldn't it generate around 3.5 volts AC?
Cheers,
Zaphod
Further to my previous post: Found my problem, fairly easily solved. The service guy who came out here (supremely un-motivated) told me the sensor "counts teeth" So I assumed there were magnetic plates inside the flywheel around the perimeter. I should have just discounted the guy as an idiot. Rotated the flywheel until I saw the mag block, measured the distance to mid mag block from the shroud backing plate (29.87 mm or 3 cm including midpoint mark on the sensor) fabricated a block from a piece of pine, drilled and tapped the backing plate and mounted the sensor so I can get at it from below the oil cooler. No one can tell me Kohler couldn't have done it this way to begin with, alright: maybe they would have used aluminum instead of pine, but the repair works, is adjustable and in my hostile climate a welcome respite from service calls at $90 per hour including travel. Booyah!
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Old 11-19-2018, 08:12:42 PM
Zephyr7 Zephyr7 is offline
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Default Re: Kohler 12 RES Installation

Magnetic pickup speed sensors do “count teeth”, and they don’t need any magnet on the flywheel to work. Mag pickups sense the variation in metal distance between the sensor and the teeth as they go by (the top of a tooth is a shorter distance than to the bottoms of the gap between adjacent teeth.

The overspeed condition is usually sensed by something other than the mag pickup. By using a seperate sensor, overspeed conditions caused by a failed mag pickup can be detected.

I’d advise against using wood to make mounting brackets on a genset. Metal would be much better, steel or aluminum. If you need something easier to work, try a piece of acetal (also known as Delrin). It’s a very durable plastic but still easier to work than metal. I wouldn’t trust wood to work long term anywhere tight tolerances are needed.

Bill

Last edited by Zephyr7; 11-20-2018 at 12:56:39 PM.
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  #16  
Old 11-24-2018, 06:29:49 PM
zaphod zaphod is offline
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Default Re: Kohler 12 RES Installation

Redesigned my system, using a Ford crankshaft sensor, I put inside a modified 1/2 ID plumbing fitting and attached to the shroud plate with a metal bracket. I shimmed it at 048" and it fired right up. The sensor is now under the oil cooler, readily available. Not too pretty but very practical.

Oh yeah: total cost: $21.25.
Cheers,
Zaphod
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  #17  
Old 11-24-2018, 11:52:40 PM
Zephyr7 Zephyr7 is offline
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Default Re: Kohler 12 RES Installation

Just make absolutely sure your setup is solid. If the sensor pops off and gets wound around a shaft youíll be having a very bad day. Loose sensors will make for erratic speed too which can cause all kinds of problems for electrical equipment.

Be careful. Kludges have a way of coming back to haunt you later.

Iím not sure why youíre so concerned with replacing a mag pickup anyway. They are very reliable and rarely fail.

Bill
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  #18  
Old 11-27-2018, 05:02:50 PM
zaphod zaphod is offline
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Default Re: Kohler 12 RES Installation

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Originally Posted by Zephyr7 View Post
Just make absolutely sure your setup is solid. If the sensor pops off and gets wound around a shaft youíll be having a very bad day. Loose sensors will make for erratic speed too which can cause all kinds of problems for electrical equipment.

Be careful. Kludges have a way of coming back to haunt you later.

Iím not sure why youíre so concerned with replacing a mag pickup anyway. They are very reliable and rarely fail.

Bill
Hi,
Because the unit wouldn't run at all without it. I can't get a straight answer from Kohler here and replacing the speed sensor solved my problem.
Now I have an under-voltage problem After running perfectly, the set now shuts down after 10 seconds with UU code for under voltage. I found a blown fuse, replaced it, and the set ran for about 10 minutes, then blew the fuse. Now with proper fuses in place, it still shuts off and gives me the UU code. Any ideas?
Cheers,
Zaphod
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  #19  
Old 11-27-2018, 06:14:38 PM
Zephyr7 Zephyr7 is offline
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Default Re: Kohler 12 RES Installation

What voltage is it actually producing while running? If it puts out correct voltage, but shuts down on under voltage, then your undervoltage trip is set too high and needs to be lowered. If it’s putting out low voltage, then I’d guess the regulator needs adjustment or may even have failed.

A blown fuse makes me suspect wiring issues or something in a winding, but let’s hope for now it was either a too-small fuse, or a fluke. A bad regulator trying to go full field could have popped a fuse too.

Bill

Last edited by Zephyr7; 11-27-2018 at 10:41:14 PM. Reason: Said overvoltage but meant undervoltage
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  #20  
Old 11-27-2018, 07:28:15 PM
Birken Vogt Birken Vogt is offline
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Default Re: Kohler 12 RES Installation

Is it the fuse in series with the auxiliary (regulator power) winding? 55/66 IIRC?

High resistance brushes or some other excitation problem can cause that fuse to blow, due to the regulator circuit needing higher power than normal.

Just speculation here.

[Based on extensive experience with these. This would be a rare problem but not unheard of.]
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