Kohler 7.5A - Generator Inspection and Service; General Inspection and Service

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Table of Contents2
Safety Precautions3
Introduction and Specifications5
Generator Specifications5
Engine Specifications5
Service and Adjustment Points6
Oil Specifications7
Fuel Specifications7
Oil Change7
Oil Filter7
Operation8
General8
Prestart Checklist8
Starting-Stopping (Remote)8
Test Operation9
Automatic - Models 7.5A9
Automatic Controller, Solid State Circuitry9
Reset Procedures10
Scheduled Maintenance11
Troubleshooting12
Remote - Models 7.5R12
Troubleshooting Remote - Solid State Circuitry - Models 7.5R12
Remote Controller - Solid State Circuitry - Models 7.5R14
Troubleshooting Automatic - Solid State Circuitry - Models 7.5A15
Automatic Controller - Solid State Circuitry - Models 7.5A17
Relay Circuitry18
Remote Controller - Relay Circuitry - Models 7.5R18
Troubleshooting Remote - Relay Circuitry - Models 7.5R19
Controller21
Solid State Circuitry21
Fuses21
10 Amp Fuse (below Battery Charging Switch)21
Harness Assemblies22
Battery Charging22
Circuit Boards22
Voltage Checks22
Sequence of Operation23
Remote-Models 7.5R23
Circuit Board Pin Identification23
Automatic (Load Demand)-Models 7.5A24
Sequence of Operation Schematic24
Controller, Relay Circuitry25
Circuit Board Identification26
Starting27
Running27
Overcrank Shutdown27
Low Oil Pressure (LOP) Shutdown27
High Water Temperature (HWT) Shutdown and High Cylinder Head Temperature (HCHT) Shutdown28
Generator Disassembly29
Disconnecting Wiring29
Slip Ring - Brush Cover29
Removing Controller29
Locking Brushes and Removing Speed Sensor30
Vibro-Mounts30
Over Bolt Removal30
Stator Leads 33 and 4430
End Bracket Removal31
Stator Removal31
Striking Thru Bolt31
Rotor Removal31
Adapter Removal32
Separating Stub Shaft and Flywheel32
Remove Flywheel and Adapter32
Stub Shaft Removal32
Generator Inspection and Service33
Generator, Cross Sectional View33
End Bracket Assembly34
Generator Parts Identifications34
Build-Up Circuit35
Separate Field Excitation35
Brushes36
Slip Rings36
Maintenance36
Normal Brush Wear36
Rotor37
Stator37
Exciter Voltage Regulator37
Wiring Diagram - Voltage Regulator Field Test38
Speed Sensor (Solid State Only)39
Mounting39
Voltage Regulator Terminal Identification39
Interlock Circuit Board (Solid State Only)40
Removal40
Speed Sensor Test40
Generator Reassembly41
Coat Stub Shaft41
Installing End Bracket41
Torque Thru Bolt41
Speed Sensor Air Gap42
Backfire Flame Arrestor, Fuel System, Governor43
Carburetor43
Fuel Collection System43
Adjustment43
Choke44
Inspection44
Troubleshooting Choke44
Backfire Flame Arrestor and Adapter44
Governor45
Speed Adjustment45
Sensitivity Adjustment45
Choke Adjustment45
Cooling System46
Water Cooled Manifold46
Heat Exchanger47
Direct47
High Temperature Cutouts47
Belt Tension48
Ignition System49
Operational Test49
Timing Magneto to Engine49
Magneto Rotation and Firing Order49
Wiring Diagrams50
Wiring Diagram - Remote Solid State - Models (7.5R); 120, 120/240-Volt50
Wiring Diagram - Automatic Solid State - Models (7.5A); 120-Volt51
Controller Interconnection Schematic (Solid State)52
Wiring Diagram - Remote Relay - Models (7.5R); 120, 120/240-Volt53

Kohler 7.5A - Generator Inspection and Service; General Inspection and Service

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