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Kohler Generators

Kohler 12.5RCOP63 Spec. 96603C Serial 010774

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Old 02-06-2019, 05:57:57 PM
Rjvega Rjvega is offline
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Default Re: Kohler 12.5RCOP63 Spec. 96603C Serial 010774

Thank you Vanman for the reply. I am going to replace the rectifer although I'm not 100% on checking the Selenium Rectifier to verify its failed. The transformer spec is not in the diagram. Do you happen to know what it is and how to test it?

The three relays coil resistance varies widely. I would to source-like replacement relays for this unit. 233180 relay is used twice and the 233059 once. I found a spec for the 233059 that said it was a DPDT 10A 12V 120Ohm relay. (not close to any of my readings) I have not been able to find a spec for the 233180 relays. I measured coil resistance on the three relays and got ICR 475 ohms on CC 15 ohms and CR 64 ohms.

The wire to the start switch, both inside the controller and behind the remote panel (RV) burned.
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Old 02-06-2019, 07:19:46 PM
Vanman Vanman is offline
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Default Re: Kohler 12.5RCOP63 Spec. 96603C Serial 010774

Wow, lucky it didn't burn down the RV. Scary. Definitely want to add a fuse or two as appropriate.

The rectifier may well still be good. Mine was. If it had failed open under load the resulting physical damage to it and the transformer would be readily apparent. This is the time to change them. Before their failure has ruined the transformer.

Odds are the transformer is good so long as it passes a visual inspection. Could verify that the windings are open circuit to the core. As per the schematic, two of the windings are connected internally at one end. The other should read open circuit to the joined pair.

It is a special transformer. Unlikely that anything off the shelf would be suitable. Another fellow on here had his destroyed when the rectifier failed. He had it rewound at considerable expense IIRC.

Can you post some photos of your set?

You can post photos directly to this site. Just scroll down below the reply field, and you will see the necessary places to click and so forth.

About Colburn Power. Before you order anything, I would call them and verify that they actually have the item that they list on their website. Took me a couple of months to get an order because of one item I ordered that they didn't actually have.
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Old 02-06-2019, 09:57:29 PM
jack0 jack0 is offline
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Default Re: Kohler 12.5RCOP63 Spec. 96603C Serial 010774

Nice and with a Perkins. Pictures please.
I believe the relays in this plant are nothing special. 12v dc for coil clearing and crank-run. 120v ac for cr1. You could get them from McMaster-Carr, Graingers etc. Might be cheaper than going through Kohler.

It kind of sounds like there are some issues in the control wiring. I would go through everything and clean up the wiring. Relays are not expensive.
Now that you have a wiring diagram, should be straight forward.

There are some older posts by LWB250 on sequence of operation you might find interesting.

I find it kind of odd that the remote start switch and the meter are connected. You would think that the remote switch wires would run straight to terminals 3-4 on the generator terminal board.
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