About a year ago my Kohler 7KW generator bit the dust on the way to Florida. Having just 85 hours on it, I was sure it was nothing serious. A year and $3000 later I will state how wrong I was!

It turns out the stator on these Kohlers can have a fatal flaw in thin wiring. Here is a photo of the part. It alone was $1600. Thankfully, for the lagging economy, Barth saw no need to build my generator on a slide, so the front end was disassembled on my Monarch to get the gennie out.

Anyway, all is now well and I thank Tony and his son at Back-Up Power in Orlando for being some of the nicest folks I have ever had the pleasure of dealing with. They are worth the trip from anywhere in Florida in my humble opinion. And I say that after unexpectedly spending $3K!!!
Corey

I have a Kohler 7.5 kw generator that runs at 80 volts when it gets wet. If I turn off the breakers and let it warm up, I get 116 volts. How did yours act when it blew?

Mine stopped running.

It is a diesel and has a circuit that will shut down the generator if it is not providing adequate voltage. I was able to eliminate the engine being a problem by jumping 12v power to the fuel solenoid (removing fuel or air is the only way to shut down diesels since they don't have an electrical system like a gas).

After much amateur troubleshooting I was able to determine the gennie put out 110V on one side and was dead the other. I then replaced the regulator as that seemed the most likely culprit, but it was not the issue.

Tony, the owner of Back Up Power, eliminated each device first by installing a replacement temporarily. Unfortunately, it ended up being the stator, which as can be seen in the picture, is pretty much the whole generator housing.
Corey

My generator is not on a slide either. This has been a wonderfull example of how miserable things can be when equipment is not manufactured right the first time. I bet (after this experiance), you would gladly have given the extra 50 bucks to use better wire. Too bad Barth never made generators

Good to hear your back up and running again.
Sorry to hear about the price but I am sure it's alot cheaper than buying a new one and with the great shape your coach was in it's pretty close to being new.
I have the same location problem with mine. Not much room looking down through that access door in the coach floor.

Was great meeting you folks at the GTG and hope to see you all soon.

Say Hi to Dominic from uncle ED.

Thanks for the words of encouragement.

Dominic says hi back. Hope you're having a great winter! Hope to see you soon.

Corey, Cheri, Dominic

I jacked mine up with a floor jack and a large 3/4 inch thick piece of plywood. I then pulled it out from under the Barth and did my repairs. Not fun!

I don't have a solid surface for a jack, so I made ramps from 2x8s; here're the photos of the genset swap.