Witness the First Run of a Vintage 1940s Kohler Generator!

Table of Contents

1. Introduction
2. Background on the Kohler generator set
3. Upgrades and improvements made to the generator set
4. The control box and transfer switch
5. Battery charging and power supply
6. Analysis of the control panel and its components
7. The crank disconnect switch and its function
8. Testing the generator set
9. Performance with load and external gas supply
10. Conclusion

Introduction

In this article, we will be taking a closer look at the Kohler generator set that was recently discovered and restored. We will explore the background of the generator set, including its specifications and unique features. Additionally, we will discuss the upgrades and improvements made to the unit to ensure reliable operation. We will also delve into the control box and transfer switch, exploring their functions and operation. Furthermore, we will analyze the battery charging system and power supply setup. An in-depth examination of the control panel and its components will be provided, shedding light on their roles and functionalities. We will also explore the function of the crank disconnect switch and its importance in starting and operating the generator set. Finally, we will test the generator set's performance under load conditions and evaluate its overall reliability. So let's dive into the world of the Kohler generator set and uncover its intriguing features and capabilities.

Background on the Kohler generator set

The Kohler generator set is a 32-volt start unit, originally designed for emergency use. The model number 10E62 indicates its classification as an emergency start plant, meaning it is fully automatic in startup and shutdown procedures. It utilizes three 12-volt batteries, providing a total of 36 volts for smooth operation. The generator set incorporates a transfer switch within the control box, allowing for seamless transition between utility power and generator power. This feature ensures a continuous and uninterrupted power supply in emergency situations. The transfer switch consists of two contactors, one for the utility side and one for the generator side, enabling the load to be directed appropriately. When utility power is available, the contactor for the utility is engaged, allowing the power to flow through to the load. In the event of a utility power failure, the control system automatically starts the engine and activates the contactor for the generator, ensuring a steady power supply from the generator to the load.

Upgrades and improvements made to the generator set

During the restoration process, several upgrades and improvements were made to the Kohler generator set. The original battery cables were replaced to ensure safe and reliable connection to the batteries. All non-original wiring was also removed and replaced with new wiring. The control box, which houses the transfer switch, remained intact but was modified to accommodate additional features. However, a selenium rectifier, used for battery charging, was found missing and substituted with a small bridge rectifier unit. While this modification may have affected the charging efficiency, it did not significantly impact the overall operation of the generator set. Other components, such as the voltage regulating resistor and additional resistors, were present in the control box, but their exact function is yet to be determined. Despite these modifications, the generator set remained in its original condition, showcasing its resilience and durability over the years.

The control box and transfer switch

The control box of the Kohler generator set plays a crucial role in its operation and functionality. It houses the transfer switch, which facilitates the seamless transition between utility power and generator power. The transfer switch consists of two contactors, one for the utility side and one for the generator side. These contactors act as a 3-way switch, allowing the load to be directed to either the utility or the generator, depending on the availability of power sources. When utility power is present, the contactor for the utility side is engaged, enabling the power to flow through to the load. In the event of a utility power failure, the control system de-energizes the contactor for the utility and activates the contactor for the generator. This action ensures that the generator's power is directed to the load, maintaining an uninterrupted power supply. The contactors are mechanically interlocked to prevent any possibility of cross-connection between the utility and the generator, ensuring safety and reliability.

Battery charging and power supply

The Kohler generator set requires a reliable battery charging system for optimal operation. The control box originally incorporated a selenium rectifier, which served the purpose of battery charging. However, this rectifier was found missing during the restoration process and was substituted with a small bridge rectifier unit. While this modification may have affected the charging efficiency, it did not significantly impact the overall functionality of the generator set. The battery charge transformer, located within the control box, ensures a steady and regulated charge to the batteries. The power supply for the generator set is provided by three 12-volt batteries, connected in series to create a 36-volt system. This voltage configuration ensures sufficient starting power for the generator set, allowing it to operate reliably.

Analysis of the control panel and its components

The control panel of the Kohler generator set contains various components that contribute to its operation and monitoring. While some components, such as the voltage regulating resistor and additional resistors, have yet to be fully understood in terms of their function, others play critical roles in controlling and monitoring the generator set. The control panel incorporates an engine monitoring controller, which ensures the safe and efficient operation of the generator set. This controller monitors various parameters such as oil pressure, coolant levels, and engine speed to prevent any potential damage or malfunctions. Additionally, the control panel includes various switches and indicators for easy operation and monitoring. A thorough understanding of the control panel and its components is crucial for effective control and maintenance of the generator set.

The crank disconnect switch and its function

One intriguing component of the Kohler generator set is the crank disconnect switch, located on the control panel. This switch, equipped with a mercury switch mechanism, serves a vital function in the starting process of the generator set. When the generator set is called to start, the crank disconnect switch closes, initiating the cranking of the engine. Once the engine reaches a sufficient speed and the governor closes the throttle, the mercury switch within the crank disconnect switch opens. This action de-energizes the starting contact, disconnecting the DC power from the armature and allowing the generator set to run under its own power. The crank disconnect switch ensures a safe and controlled starting sequence, protecting the generator set from any potential damage or malfunctions.

Testing the generator set

After completing the restoration and making necessary upgrades, the Kohler generator set was put to the test to evaluate its performance and reliability. With a small amount of load connected, the generator set was started to observe its operation under normal conditions. While some minor issues, such as a slight engine miss, were detected, the generator set ran relatively well. It provided a stable power supply to the load, demonstrating its reliability and functionality. The oil pressure and temperature were within acceptable limits, indicating proper lubrication and cooling of the engine. However, further adjustments and fine-tuning may be required to optimize the performance of the generator set. Overall, the generator set showcased its ability to deliver consistent and reliable power, reaffirming its value as an emergency backup system.

Performance with load and external gas supply

To further assess the generator set's capabilities, it was tested with a moderate load and an external gas supply. The load was connected to the generator set, simulating a real-world scenario where the generator would provide power to essential appliances or equipment. The generator set performed adequately, supplying the load with the required electrical power. However, due to a temporary hose setup and an extended hose length, a slight pressure drop was observed in the gas supply, affecting the performance of the generator set. This issue could be rectified by shortening the hose length and ensuring a more direct and efficient gas supply. Despite these challenges, the generator set demonstrated its ability to handle load conditions and maintain a steady power output. With proper setup and optimization, it can serve as a reliable power source in emergency situations or off-grid locations.

Conclusion

The Kohler generator set presented an intriguing restoration project, showcasing its unique features and robust design. Through upgrades and improvements, the generator set was brought back to reliable operating condition, ensuring a consistent power supply. The control box and its incorporated transfer switch provided a seamless transition between utility power and generator power, guaranteeing uninterrupted power supply in emergency scenarios. The battery charging system and power supply setup ensured the generator set had sufficient starting power and reliable battery charging capabilities. The control panel, equipped with various monitoring components, allowed for effective control and oversight of the generator set. The crank disconnect switch played a crucial role in the starting sequence, safeguarding the generator set from potential damage. Testing the generator set under load conditions showcased its ability to deliver stable power and perform adequately. While some minor adjustments and optimizations may be necessary, the Kohler generator set proved its worth as a reliable backup power source. Whether in emergency situations or off-grid locations, this generator set can provide the necessary power supply to meet essential needs.

Highlights

• The Kohler generator set is a 32-volt start unit designed for emergency use.
• The control box houses a transfer switch, allowing for seamless transition between utility power and generator power.
• Upgrades and improvements were made to ensure reliable operation, including replacement of battery cables and modification of the control box.
• The crank disconnect switch, equipped with a mercury switch mechanism, plays a vital role in the starting process of the generator set.
• The generator set demonstrated its ability to deliver consistent, reliable power under load conditions.
• Optimization of the gas supply system can improve the performance of the generator set.
• The Kohler generator set serves as a reliable backup power source in emergency situations or off-grid locations.

FAQ

Q: What voltage is the Kohler generator set designed for?

A: The Kohler generator set is a 32-volt start unit.

Q: What is the purpose of the crank disconnect switch?

A: The crank disconnect switch serves to initiate the cranking of the engine and disconnect the DC power once the engine is running.

Q: Can the generator set handle load conditions?

A: Yes, the generator set is capable of supplying power to a moderate load.

Q: What are the key features of the control box?

A: The control box houses the transfer switch, various monitoring components, and the necessary wiring for the generator set.

Q: Is the generator set suitable for off-grid locations?

A: Yes, the generator set can provide a reliable power source in off-grid locations or during emergency situations.