Köhler generator won’t work

Hello all. I have a problem with my generator. Already read a lot of post but now I am stucked. When survived the boat last year with previous owner the generator worked. Must say only tested short time. After our ship arrived in the Netherlands it didn’t work anymore. Last days I try to make it run but no luck so far.

Köhler generator model: 13.5CCOZ
Problem: Engine starts, but does not continue to run after start switch is released.

https://youtu.be/eHxAe-KUASg
What I have tested: In the manual I read at the troubleshooting section that 3 sensors can cause this problem. They are normally closed sensors that are attached in series. I measured the HWT and HET sensor and they didn’t had connection to ground. The LOP sensor is open and after start and when the oil pressure is good the lop sensor is closed,
I disconnect the wire from the LOP sensor and messured the wire. Strange I measure connection to ground, I followed the wire to the circuitboard and cut it there and measured the wire again and this time no connection to ground.
The circuit is, so it looks already open from circuit board.



When we bought our ship we also received a lot of parts and 1 of those parts was an old circuitboard. I changed connectors to the old board but unfortunately the same problem. Engine didn’t continu after releasing the start switch.

I also tested the fuel solenoid by holding him after start and then the generator runs.



So there must be another safety but I don’t know which one.
What I miss?

A failed voltage regulator will also cause a shutdown. Test for voltage output while holding start start switch.

but minimize the override use of the start switch as much as possible because that is harmful on the starter and possibly the flywheel.

when you do have generator running normally do not start or shut the unit down with a load.

Wanderer 290 said:

A failed voltage regulator will also cause a shutdown. Test for voltage output while holding start start switch.

but minimize the override use of the start switch as much as possible because that is harmful on the starter and possibly the flywheel.

when you do have generator running normally do not start or shut the unit down with a load.

Click to expand...

Gonna check that tomorrow. Thanks

I checked voltage regulator and under all the wires I found a 8a fuse that was broken. I replaced it with a 4a fuse and that blew up right after start. Then I placed a 10a fuse and the generator run. I turned it of after 20 sec and started again and then after couple seconds it stopped again. The fuse is still good though. Another 10a fuse was found in the wires but that fuse was good.

Then i measured output voltage while starting and I measured voltage. I didn’t press start for long time. When voltage came up I stopped.

I had 2 new relais (k20 and k25), replaced them but nu luck. Generator stopped after releasing start button.

So for 20 seconds the generator run but probably because of the 10a fuse instead of 8a I blew up something else?
But what causes that I don’t know

anyone has a direction point for me? thanks

really need some help here....

Did the voltage come up to 120?

Wanderer 290 said:

Did the voltage come up to 120?

Click to expand...

I measured both cables together for 220v and voltage came up above 160v and then I released start button

The exhaust overheat, coolant overheat and low oil pressure have been bypassed with no success.

The pcb’s were swapped with no success.

The generator does produce voltage of 160 but short of 220.
Was the voltage tested before or after the voltage regulator?

Do you have the ability to verify rpm’s?

Have the brushes been checked?

I suspect the blown fuses are caused by high amperage caused by low voltage.

If rpm is to spec my opinion is a faulty voltage regulator.

If the rpm is low check the governor.

then recheck the voltage output.

Unfortunately I don’t have the ability to check rpm.
Because you advise me not to press the start button to long I don’t know till how much voltage the generator will reach.
I measured voltage after the voltage regulator on the wires that going to circuit breaker.

when I am on the boat again i try measure again while pressing the fuel solenoid.

I am affraid that I blew something else by putting a 10a fuse.
The first run after changing the fuse was good, then on second start it was same problem: engine stopped when releasing start button.

brushes I didn’t check, is that easy to check?

Sorry for my late reaction but we had some very very hot days so it wasn’t repair time at all.
i also bought a rpm gauge and a good volt gauge with clips and no pins.

first thing i did was put the clips on the wires to measure good voltage while pressing the fuel solenoid in open position.

when hitting the start button voltage came up to 180v and then drops to 33 volts constantly. Didn’t had to measure anything else.

So this causes by a faulty voltage regulator?
Let’s see if that regulator is still available.

Did the volt regulator fix it?

ATLTiger97 said:

Did the volt regulator fix it?

Click to expand...

Well the voltage regulator didn’t fix the problem.
I got in touch with flightsystems and send the voltage regulator to them and yes it was broke. The guy who worked there was very helpful. After receiving the regulator back it run for 30 sec and then I heard a electrical failure and for sure the regulator was broken again.
The flightsystems guy run every test by email and I preformed every test. What we found was the coil that is in the gen housing was the problem. To remove the generator housing was really a lot of work.

at that moment I already spent a lot on repair cost and then a point came that i was so angry/disappointed/tired and I threw the regulator and total generator closet in the garbage. Didn’t want to spent more time too it. Also have to tell that the previous owner had some water leaks to the engine room and that there was a lot of rust on the generator. So by throwing that important parts away I knew for sure that i wouldn’t spent energy in that generator any more.

just two weeks ago I had some spare time and removed the rest of the generator. I didn’t had a crane or something so I dismantled the generator in many many small parts and the eventually I lifted the engine part with some buddy help out of the engine room. The bottom plywood was also with dirt and moisture and replaced that for a 2cm thick plastic fabric .

I am not sure yet if I place a new gen in or use that space for bicycles or something. The complet electronic on our boat I changed with converters etc so can do almost everything . 3 ac in the same time we never use and can stay off shorepower for 2 days when we don’t use the oven and airco.

It is certainly driving me a little crazy but not there yet .