Given the work you have done, you never mentioned if you have had the stator and rotor tested? if you can get it running check for DC power on the brushes. that will help isolate. If power blinks for a second, that is the control trying to flash the rotor, if the rotor has a short the controls will remove the excitation voltage. Check that before going to any major expense
SOURCE: generator runs producing no power
Hi, remove the electric control panel & check the wiring as sometimes we have seen the wires coming off the voltage change over switches.
Also some of these units you can check the connections in the rear of the alternator & if it has brushes that they are not stuck.
Another problem we have had is the trip switches have went faulty but still switch operates ok, they need to be checked with a probe type tester for conductivety.
SOURCE: electrical wiring for kohler engine
Perhaps you would enjoy the entire service manual. Here it is: http://www.asberry.net/files/TP-2379.pdf
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