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Need 6.5 KW Kohler advice, damaged brush holder.


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  #1  
Old 12-31-2018, 12:36:32 AM
Kenny Crenshaw Kenny Crenshaw is offline
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Default Need 6.5 KW Kohler advice, damaged brush holder.

I am still working on my 6.5 KW Kohler 4 cylinder gasoline L600. It looks like sometime in the past, and likely the event that sidelined this generator, was a 120 volt AC brush that hung and burned, or burned and hung, or overheated, or something that destroyed the brush, the brush tension spring, and the radio suppression capacitor. Thanks to Ebay, I found a new brush and a new tension spring. But, the brush holder is bent, rubbed and worn, and also cracked. I need to either repair the holder, or find a new one. Finding a new one could mean a whole new brush holder assembly, Kohler B-242238, because the brush holders are rivetted on. Repairing it may mean fashioning a new one out of copper, or silver soldering a patch on the burned one. I've included a photo of a good brush assembly as well as the damaged one.

Any ideas?
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Old 12-31-2018, 02:10:18 AM
Vanman Vanman is online now
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

Those are very good photos.

In photo #1, of the good brush holder, it can be seen that the fiber brush rigging disc is cracked where that terminal is. Could probably repair that with some type of adhesive, I'd think. Maybe even just run some super glue into the crack.

For the damaged brush holder, I would tend to think that filling in the crack with braze and then filing it down to the correct dimensions might be a good option.

It isn't super critical. It needs to generally hold the brush in position, but by no means be tight. And of course it does not ordinarily carry any significant current, the vast majority passing through the pigtail instead.
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Old 12-31-2018, 01:34:21 PM
Zephyr7 Zephyr7 is offline
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

Make sure to clean the crack in that fiber disc really well before gluing, itís probably full of dust which will make for a weak glue bond. Iíd blast it with canned air, then use some isopropyl alcohol to get any oily residue. Once that dries, use some thin glue that will wick into the crack by capillary action. A thin acrylic adhesive like superglue would probably work well. If you canít glue that disc well enough, it wouldnít be too difficult to fabricate a new one from either type XX phenolic sheet (which will look correct in a restoration job), or G10 sheet (much stronger, but it is a greenish white color and wonít look right). Glastic would work too but is normally bright red.

The big rusty nut looks cracked too. Probably best to just replace that.

I agree about brazing that brush holder. You could probably use silfoss (special silver brazing rod) too.

Bill
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Old 12-31-2018, 01:37:44 PM
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Billy J Shafer Billy J Shafer is online now
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

Kenny I didn't know you were over here also. If anyone can help you these guys can.
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Old 12-31-2018, 03:15:16 PM
Kenny Crenshaw Kenny Crenshaw is offline
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

Thanks guy! Are you sure that is a crack and not a spider web?
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Old 12-31-2018, 05:03:27 PM
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

Good point!
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Old 12-31-2018, 10:50:59 PM
jack0 jack0 is offline
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

I would think you could repair the holder pretty easily when its off the disc.
I had some loose rivets which I replaced with 6-32 brass fasteners.
The rivets on mine were brass and were hollow. I used a small file on the other side of the disc to free the rivets.

I believe the rivets for that brush holder go straight through the disc and do not support any commutator brush holders, which will make the job easier.

Happy new year.
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Old 01-01-2019, 12:48:15 AM
Zephyr7 Zephyr7 is offline
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

If you replace rivets with brass screws, make sure to use locking hardware so the vibration doesnít work them loose. Iíd use a stainless steel nylock (I donít think you can get them in brass). Rivets have the advantage of being pretty much vibration proof.

If you want to use a brass nut, threadlocker will work, use loctite red since youíll have a very small amount of thread in a small fastener so not much area for the loctite to stick to.

Bill
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Old 01-03-2019, 08:49:06 PM
nblack nblack is offline
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

Or, find another donor unit, and swap out the brush holders.... keep the rest for parts. Did you try Wavetop Technology, and talk to Jim? He is a great guy.
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Old 01-04-2019, 10:03:25 PM
Kenny Crenshaw Kenny Crenshaw is offline
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Default Re: Need 6.5 KW Kohler advice, damaged brush holder.

I talked to Jim weeks ago, but I cannot remember why we could not get together. Seems like he would not call or email, so I bought a bunch of parts from another vendor.
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