Questions about M18 flywheel removal to repair charging.

BPR · Oct 10, 2020

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 · Oct 10, 2020

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 · Oct 11, 2020

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

jchamberlin · Oct 20, 2020

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 · Oct 20, 2020

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

BPR · Oct 23, 2020

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 · Nov 18, 2020

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

gary noblit · Nov 19, 2020

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 · Nov 19, 2020

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!