Kohler 7.3E Service Manual

TP-5986 4/03 Table of Contents
Table of Contents
Safety Precautions and Instructions I.........
Introduction i...............................
Service Assistance ii.........................
Service Information ii..............................
Product Information ii..............................
Service Parts/Publications iii..................
Routine Service Parts iii............................
List of Related Literature iii.........................
Section 1 Specifications 1....................
1.1 General 1..................................
1.2 Engine 1...................................
1.3 Fuel 1......................................
1.4 Cooling 1...................................
1.5 Generator 2.................................
1.6 Torque 2...................................
1.7 Service Views 3.............................
Section 2 Scheduled Maintenance 5...........
2.1 General 5..................................
2.2 Lubrication System 5.........................
Section 3 Intake and Exhaust System 7........
3.1 Backfire Flame Arrestor 7.....................
3.2 Exhaust 7..................................
Section 4 Fuel System 9.....................
4.1 General 9..................................
4.2 Float Bowl Vent System 9.....................
4.3 Fuel Pump and Filter 9.......................
4.4 Fuel Pump Troubleshooting 10.................
4.5 Carburetor Troubleshooting 10.................
4.5.1 Hard Starting 10......................
4.5.2 Stalling 10...........................
4.5.3 Flooding 11..........................
4.5.4 Hunting 11...........................
4.5.5 Leaking Carburetor 11.................
4.6 Governor 60 Hz to 50 Hz Conversion 11.........
Section 5 Cooling System 13..................
5.1 General 13..................................
5.2 Closed Heat Exchanger 14.....................
5.3 Check and Fill Coolant 14.....................
5.4 Flush and Clean Cooling System 14.............
5.5 Impeller 15..................................
5.6 Siphon Break 16..............................
5.7 Anticorrosion Zinc Anode 17...................
5.8 Generator Storage 18.........................
Section 6 Controller Troubleshooting 19........
6.1 Sequence of Operation 19.....................
6.1.1 Start 19.............................
6.1.2 Run 19..............................
6.1.3 Stop 20..............................
6.2 Engine Safety Shutdown Switches 20...........
6.2.1 Low Oil Pressure (LOP) Shutdown 20...
6.2.2 Loss of Coolant Switch (LCS)
Shutdown 20.........................
6.2.3 High Engine Temperature Switch
(HET) Shutdown 20...................
6.2.4 Controller Circuit Board 20.............
6.2.5 Troubleshooting 21...................
Section 7 Generator Troubleshooting 25........
7.1 General 25..................................
7.1.1 Troubleshooting 25...................
7.1.2 Separate Excitation 26................
7.2 PowerBoost IIIE Voltage Regulators 27..........
7.2.1 Voltage Regulator Test 27..............
7.2.2 Voltage Regulator Adjustment 28.......
7.3 Rotor 29.....................................
7.4 Stator 29....................................
7.5 Brushes 31..................................
Section 8 Component Troubleshooting 33......
8.1 Engine/Generator Components 33..............
8.2 Remote Panels (Optional) 35...................
Section 9 Generator Disassembly/
Reassembly 37...............................
9.1 Disassembly 37..............................
9.2 Collector Ring and Bearing Replacement 39......
9.3 Reassembly 39...............................
Section 10 Wiring Diagrams and Voltage
Reconnection 41..............................
10.1 Schematic Wiring Diagram 42..................
10.2 Point-to-Point Wiring Diagram 43...............
10.3 Reconnection Diagram 100--120 V,
60 & 50 Hz 44................................
10.4 Reconnection Diagram 100--120/200--240 V,
60 & 50 Hz 44................................
10.5 Reconnection Diagram 220--240 V, 50 Hz 44.....
10.6 Remote Start Panel 44........................
10.7 Remote Start and Two-Meter Panel 45..........
10.8 Remote Start and Four-Meter Panel 45..........
Appendix A Abbreviations A-1................
Appendix B Common Hardware Application
Guidelines A-3...............................
Appendix C General Torque
Specifications A-4............................
Appendix D Common Hardware
Identification A-5.............................
Appendix E Common Hardware List A-6.......

Kohler 7.3E Specifications

General

Brand	Kohler
Model	7.3E
Category	Portable Generator
Language	English