Questions about M18 flywheel removal to repair charging.

[BPR]

I have a CCC 782 with a Kohler M18. It's charging at about 13 volts at WOT. When loading the battery with lights & PTO engaged this is adequate to charge the battery. After troubleshooting with a voltmeter the problem appears to be with either the flywheel magnets coming loose or the stator is damaged. From what I can tell I will need to remove the engine to remove the flywheel? Can anyone give any feedback on this or direct me to a thread that discusses this situation? Thanks!

 

[jstich]

Yes you do need to remove the engine to get to the flywheel and stator. But BEFORE you do that download this manual. http://resources.kohler.com/power/kohler/enginesUS/pdf/tp_2204_b.pdf
Go to section 8 page 8.9 This chart will tell you how to diagnose the charging system. Probably the most important is test 2 measuring the AC voltage output from the stator. If it not 28 volts you have a stator problem. If it is 28 volts you have a regulator, battery or grounding problem.
Hope this helps....

 

[BPR]

Thanks for the reply. I have the manual & followed its testing procedures. Next I will be removing the engine.

 

[jchamberlin]

I have repaired an M18 that would run the lights but couldn't charge the battery by gluing all the magnets back in place with metal-flake impregnated epoxy. I used a 1/4" drill bit to space them around the inside perimeter of the fly wheel. The hardest part was maintaining the proper polarity of each magnet.

 

[BPR]

Thanks for the feedback. I’ve seen a few YouTube videos repairing the flywheel like you did.

 

[BPR]

I removed the motor this afternoon. Four of the 6 magnets had come loose. I removed the other two by tapping lightly with a hammer & punch. Cleaned the flywheel & magnets with a sanding flap wheel attached to a drill. Identified the polarity Cleaned surfaces with acetone & epoxied with JB Weld. Used 1/4" bolts as spacers. This youtube video was helpful & somewhat hummorus.

 

[jchamberlin]

Thanks for reporting back. Glad it worked out for you.

 

[gary noblit]

Mr. Chamberlin, how does one ascertain correct polarity of magnets.?? Many mentions over time but no explanation for us slow thinkers...I have serious hangups on all electrical systems but I fight thru it....

 

[BPR]

My last post was my first try. I used the wrong method identifying the polarity of the magnets first try. I had to remove the flywheel & remove the magnetic I epoxyed on. I've attached a photo of the way I properly identified polarity of magnets & a photo of how they need to be attached to the flywheel. Tractor is charging & running well now. Ready for snow!

 

[gary noblit]

Brian,thank you very much for the extra effort of posting pics....

 

[BPR]

Brian,thank you very much for the extra effort of posting pics....

You're welcome!