Kohler Powerhouse 5000 Watt Generator

[Skywatcher]

Greetings All

Customer brought in a 1983 Kohler Powerhouse 5000 watt portable generator in pieces as it had no spark. His father-in-law who is a decent automotive mechanic had a go at fixing the ignition system, but could not get it to produce a spark, so gave up on it. After checking all the components of the system and reassembling the unit, I have good spark and the engine runs properly at 3680 RPM now that I've cleaned out the fuel system.

There is a single wire from the alternator to the condenser on the engine which I'm assuming is some sort of engine kill system. When I was assembling and testing the ignition system, as long as this wire was not connected, I had spark. Once the engine was running, connecting the wire made no difference until I attempted to initialize the alternator. Here's where my knowledge of these units ends, so I'm hoping there are a few generator aficionados who can either help me or point me in the right direction.

On the business end of the alternator, there are 3 receptacles (1 x 220 volt & 2 x 110 volt), 2 breakers and 1 square button that is to be pushed once the engine is running to activate the alternator. When the button is pushed, it kills the spark thus stopping the engine. If the button is released before the engine has stopped turning, the spark resumes and the engine picks up again. I suspect this was the most likely the initial cause of the no spark condition that caused the unit to shut down in the first place. Any thoughts or ideas welcome.

Unit information:
1983 Kohler 5000 Watt portable generator
Model: 5CM65-HS
Type: 87554A
Ser Nº 098312

[KE4AVB]

If my info is correct you need a copy of the Kohler TP-5124 Service Manual. I don't have a copy here but someone here may or you can try the fellows over on SmokStak.com forum (generator forum section).

[Skywatcher]

Hi KE4

After a little more checking, the gen-set does produce power, but once any sort of electrical load like 3000 watts is applied, the engine cuts out and in again every so often. I've decided this is a case for an electrical specialist and have advised customer accordingly. All the best,

Sky