Cas8101
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Kohler command 12.5
Working on a miller welder/generator with a Kohler. Found several issues but the one I’m looking to address currently is on the cylinder head. Where the muffler attaches to the head around the carb side bolt threads it’s all “washed out” by exhaust gases I’m guessing. Could I repair this with some steel putty? Is this a sign of a blown head gasket? Is this a sign of issues with the exhaust valve? The muffler mounting bolts were really loose
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SRTsFZ6
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Re: Kohler command 12.5
2025/07/13 14:46:24
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Cas8101
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Re: Kohler command 12.5
2025/07/13 16:47:33
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Having issues posting pictures but the issue is not with the muffler, it’s with the cylinder head where the muffler mounts to the head. It’s missing metal around one of the bolt holes. Kohler Ch12.5S I believe is the model number. And no studs, bolts go through muffler and into the head
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SRTsFZ6
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Re: Kohler command 12.5
2025/07/13 19:35:03
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Cas8101
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Re: Kohler command 12.5
2025/07/13 19:51:49
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Yea I’m not to sure bout the JB weld idea either but I did buy something they make called extreme heat. It’s like a hardening epoxy paste product that is supposed to be good for 1000 degrees and lists exhaust’s as something it’s used for. May try it for chits and giggles. I can’t weld aluminum and would have to take it to someone for that repair. Mainly trying to get this thing running to verify power output from weld leads and the 110 receptacles before diving any deeper or sinking much money into it. It’s 1995 Miller Bluestar 180k with about 700 hours on the clock
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SRTsFZ6
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Re: Kohler command 12.5
2025/07/13 21:04:06
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Ah, ok Also, if you can put studs into the head, if enough room around the muffler, would make a stronger point- IE, no threads in the head having a bolt turning thru it. The stud is stationary, nuts after, to pull the muffler in... Good luck and plz post back how it goes.. .
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Cas8101
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Re: Kohler command 12.5
2025/07/14 20:18:01
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☄ Helpfulby SRTsFZ6 2025/07/15 06:31:22
Waiting on a couple parts for the carburetor and a new exhaust gasket. Re sealed the OHV cover today with the right stuff grey. Will update on Thursday when I attempt to fire her up
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Cas8101
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Re: Kohler command 12.5
2025/07/17 09:01:54
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Got it semi put back together last night to attempt to run it and check power output from welding leads/receptacles. It still runs the same, which is starting to briefly then backfire out the intake and possibly the exhaust as well. I’ve pulled vakve cover and checked rockers and push rods prior to this so pretty sure valves are not the issue. Believe it’s ignition or out of time. Gonna check spark plug and coil but I’m pretty sure I’m gonna find out I have a sheared flywheel key if I pop the flywheel off. Will report back with my findings
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Cas8101
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Re: Kohler command 12.5
2025/07/19 13:00:39
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Ok so to confirm valves are not the issue I did a leak down test today. Only 10 percent leak down so good there. Have good compression, valves are indeed working, have spark, have a working carb. Still runs and dies and backfires. So I have not pulled flywheel to check key but don’t think it’s sheared when rotating flywheel by hand the magnet is just clearing the ignition coil on TDC so that seems to check out in my book as in time. Think I’m going to slap a new coil in it and see if that’s the issue. I put a new plug in it already even though plug was fine that was in it.
Appreciate any thoughts or expertise fellas
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SRTsFZ6
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Re: Kohler command 12.5
2025/07/19 13:26:30
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I agree, the flywheel key is probably ok. Before I'd start throwing parts at it, I would pull the flywheel just to confirm. It's easy enough to remove (no puller needed) to check. Also, if you have a "see thru" spark tester (cheap enough on Flea Bay), I'd check before buying a knock off coil (assuming the OEM coil is stupid expensive). . .
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Cas8101
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Re: Kohler command 12.5
2025/07/19 14:43:56
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I have an in-line spark tester, never used it until now but when hooked up it’s flashes consistently but the light is orange. Shouldnt it look blue if spark is strong and orangish if weak? This is what led me to further suspect the coil
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Cas8101
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Re: Kohler command 12.5
2025/07/19 17:47:42
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Ok well I’ve figured out what the issue is. When inspecting coil I decided to unplug the kill wire from it and try and start it to eliminate that as a potential issue. With that disconnected engine fired up and ran like a top. I’ve heard of this as an issue before but guess I’ve been fortunate because this is my first hands on experience with it. So is this an instant replace the kill switch? Clean up all the connectors that plug into it first before replacing? Appreciate any input.
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Cas8101
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Re: Kohler command 12.5
2025/07/19 20:01:53
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Chased kill wire from ignition coil back to switch on side of welder and where it plugged into the switch there was another wire there. Chased that wire and found it provided power to the oil pressure switch. Unplugged it from that switch to retest and wouldn’t you know it bam engine fires up and running like a top. Bad oil pressure sensor!!!
Tested all receptacle’s and they were provided 120 volts. Hooked up a light and a grinder and they ran fine. Decided to hook my welding leads up to it and burnt a rod of 6011 without issue. We are back in business baby. Need to button everything back up and give her a cleaning. She has also earned an oil change!
Minor issues still need to address. Believe she is running maybe a 100 RPM to slow. She was showing 58.5hz and tried to make adjustment on carb with no increase. Maybe need to look at the governor setup and see what I can do there. Says on the cover should do 60hz at 3750 rpm. I would think from other generators I’ve checked that it should be around 61.5hz
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SRTsFZ6
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Re: Kohler command 12.5
2025/07/20 07:13:22
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Cas8101
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Re: Kohler command 12.5
2025/07/20 13:25:49
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So there was indeed an engine speed bracket with two set screws on it that the governor spring attached too. Loosed them up slid the bracket over about a 1/4” and that brought things up nicely. Left it set at 61.8-62 hz which is roughly 3710-3720 rpm. Slightly below rated max for this machine. Gonna start cleaning up some old grime on it, wrap my wiring harness back up and just generally button things back up. But it sure appears I have a viable machine here again
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