Kohler 6.5CZ...Final chapter (HOPEFULLY!)

[tonyiiiafl]

Spent ANOTHER day in the bilge with the Kohler 6.5CZ9I MUST mention that the CZ is different from the others! I have bought parts for the 6.5GZ and they are different!) I have been looking for a governor spring forever, as they are NLA. However I found 3, and now own them. Genset was hunting all over and surging. I should have replaced the spring when I had the starter out, but it was not a bad replacement if you have the right tools, long nosed pliers and fingers you dont mind cutting. I went to replace the heat sensors, but of coursee different as they were for the GZ. (If anyone need a couple I will make a deal on them!) SO I removed the old ones and cleaned up with a wire brush so ther is good clean contact. Next the 20UF capacitor was replaced with the upgraded 25UF. Started her up and bingo. RPMS were WAY high as the new spring was tighter, putting out 135VAC and spinning at 3800. Factory states 3600 under load, and 3750 with no load to hit 60 cycles. EASY governor adjustment to dial in at 3600. SO far, she is running smooth, no surging and has not done the shut off thing as it was doing. Here are a few photos of my (so far) success.

[tonyiiiafl]

Had a video but couldn’t figure out how to upload it. SMOOTH as can be. 30 minutes now.

[RGrew176]

Looks like you have solved your issue. Glad things finally worked out in your favor. Thanks for sharing the solution. The next guy with the same issue at least has a starting point. Now hopefully you can get some new adventures aboard to post about.

[tonyiiiafl]

Thanks! I do think it was a combination of the capacitor and also the temp sensors. There was a lot of corrosion underneath them that would impeded a good reading. We shall see. Going to try it again tonight for an hour while at the slip.

[bud37]

Tony , you are going to be the, "go to guy", for these gennies when this is all over.....good job man, way to pick your way thru it all....

[Viper]

Nice going Tony and thanks for keeping us in the loop

[tonyiiiafl]

I was always one to be “baptized b y fire” and this one I was. I wrote on paper a flow chart of what would cause a shutdown, and also what would relate to non energization, and methodically followed it through. I had my mechanics all over the board with this one. At $115.00/hour it would have gotten ugly for sure plus parts. I try and not be a parts replacer but a trouble shooter. Thanks for all the support and letting me put my thoughts here, as it helped with the troubleshooting process.

[mjk1040]

U the genny man!

[tonyiiiafl]

LOL, by default! Thank you.

[KeithS]

Great Job! You realize of course that this is hardly the final chapter, the generator will think of something else for you. Your generator mechanic rate might be a little low, our rate is $150 per hour, more important it is hard to find someone willing to work on a 20+ year old, discontinued generator that has many parts NLA. So it is good to learn a little about it for yourself. The best way to be sure to get the correct parts is to look for the Spec # on your serial number tag. That refers to the way the generator was built at the factory as different boat manufacturers wanted different equipment.