Kohler 7.5 EKD generator over voltage fault

[dwhite]

Generator stopped with an over voltage fault. Reset and restarted and it repeated overvoltage fault.
When it was restarted, it ran for 10 seconds or so the voltage showed as high as 190 V

[g36]

Could be the scr ( silicon controlled rectifier ) it regulates the ac output volts. Have you downloaded the manual from the web? Should be easy to find. This will give some options too. Have you recently done anything to the genset?

[dwhite]

Thanks for getting back. I have ordered a regulator/rectifier and I’m hoping that is the issue. Rectifier is testing correctly on the DC coming out but not certain about the AC. I do have all the manuals, including operation installation service and parts. definitely want to eliminate a few things before I look at the advanced digital control

[Conquest]

Did you get it fixed?

[Conquest]

I had the same problem or still may have.
7.5EKD generator over voltage fault.
I don't think this model has a silicone controlled rectifier.
I replaced the voltage regulator/rectifier with a Chinese knock off.
It worked at home for the test then didn't work when I got out on the water. I checked the brushes because the manual mentioned brush arcing can lead to faulty regulator and or ADC main controller but the brushes look good.
I just replaced the regulator again but this time with a OEM part and this time I installed the supplied ground wire with the original ground also. It worked at home. I can't say I will be surprised if its another jinx and fails when I want to use it again but I will be hot!
This generator has 12 hours on it, I got it with 9. It's been a pain in the ass.
Fuel filter and fuel line issue, crank positioning sensor failure and replacement, remote digital gauge failure and replacement.
Now overvoltage faulting
If it wasn't so hard to get to and get out I turn it into an artificial reef.
The cost of the ADC2 is 2K so I'm trying to avoid that if I can.

[dwhite]

Finally established the problem. Required removing the generator from the boat and doing a big disassembly to get to the cause which was the stator. The stator mounting piece which is bolted with 4 bolts to the engine had loosened. It was being held by only one bolt with one bolt completely out and the other two ready to fall out. The rotor was coming in contact to the stator and caused damage to the stator and caused A straight to ground problem on a wire 55. I am now looking to find out a company that can do the rewinding rather than buying a new part. I had been in contact with Eurton Electric Who claim to be able to do the rewind but checking on their reviews I’m a little hesitant to use them.

[Viper]

Try Renown Electric in the Toronto Ontario area, they may still work on the smaller applications.... https://renown-electric.com/

Also try contacting SMD in Orillia Ontario, they've been in generator repairs for years and may have a used/parted unit lying around.... https://www.smdservices.ca/

[dwhite]

Thanks for the reply. I’ll try contacting both on Monday. The rotor checked out fine which was lucky..I found a company in the US that has new part which might be my last choice.
Had I not removed the generator from the boat to preform a few test which were too difficult to preform while installed on the boat, there could have been a disaster if the last bolt holding the stator on the block had let go.

[waybomb]

I have no genny repair experience. I would suggest getting brand new bolts of the same type, and use loctite blue.

[dwhite]

I will for sure and torqued properly. Someone in the factory was asleep at the switch and probably missed torquing them
Thanks