Kohler 7CCKM Generator Set

⚠ Fire: do not smoke or permit flame or spark near fuel system

1. Stop engine; turn main and idle fuel needles in until lightly bottomed.
2. Back out main fuel needle 2-1/2 turns, idle fuel needle 1-1/2 turns.
3. Start engine and run at half-load 5-10 minutes to warm up.
4. Turn main fuel needle in to lean limit, then out 1/4 turn.
5. Adjust idle fuel needle using same procedure.

⚠ Explosive fuel vapors: use extreme care handling fuels

1. Turn MAIN FUEL valve in until lightly bottomed; back out 1 turn.
2. Warm engine at rated rpm under full load.
3. Turn MAIN FUEL valve in until engine slows (lean), then out until full speed (~1/8 turn).
4. Stop engine; turn IDLE FUEL screw in fully, back out 1/4 turn.

1. Loosen two screws securing choke bracket to carburetor.
2. Shift position of choke assembly to adjust.
3. Above 10°F: rotate choke cover counterclockwise (leaner) to 5/16 in. (8 mm) scribe mark.
4. Below 10°F: rotate choke cover clockwise until scribe and casting marks align.
5. Tighten the two choke adjusting screws.

Tools: frequency meter

1. Adjust carburetor fuel mixture before governor adjustment.
2. Attach frequency meter; run set 5-10 minutes to operating temperature.
3. Adjust speed pot for 60 Hz (1800 rpm) or 50 Hz (1500 rpm).
4. Turn gain pot ~1/8 turn counterclockwise until stable, no hunting.
5. Verify no load and full load frequency within 0.4 Hz (120 rpm).
6. Check overspeed cutout point by manually moving throttle coupling clockwise.
7. Readjust overspeed pot as needed; reset overspeed after speed changes.

⚠ Rotating parts: do not operate without guards, screens, or covers in place

Tools: feeler gauge

1. Stop engine and cool to normal ambient temperature.
2. Rotate engine until #1 cylinder piston is at TDC on compression stroke.
3. Measure clearance between valve stem and tappet with feeler gauge.
4. Turn tappet adjusting screw in or out to attain proper clearance.
5. Rotate engine 360° and repeat adjustment for #2 cylinder.
6. Install new head gasket and reinstall cylinder heads, tightening in sequence.

⚠ Hazardous voltage; heat sink contains high voltage

Tools: voltmeter, frequency meter

1. With set off, turn remote rheostat to mid-point; turn Voltage, Volts/Hz, Stability pots fully counterclockwise.
2. Connect voltmeter and frequency meter to AC circuit.
3. Start set; rotate voltage adjustment pot to desired output voltage.
4. Rotate stability pot clockwise for minimum light flicker.
5. Adjust engine speed to cut-in frequency (56.3 Hz or 46.3 Hz).
6. Rotate Volts/Hz pot clockwise until voltage begins to drop.
7. Readjust engine speed to normal, then readjust voltage and stability pots.

Tools: ohmmeter

1. Inspect rotor for damage to pole shoes, insulation, coil windings, slip rings.
2. Install brush retainer so brushes do not contact slip rings.
3. Measure rotor resistance between the two slip rings.
4. Check rotor shorted to ground between slip ring and rotor poles/shaft.

⚠ Hazardous voltage: perform electrical service only as prescribed

Tools: ammeter, 12-Volt battery, 10 Amp fuse

1. Disconnect all leads from voltage regulator.
2. Connect ammeter and 12-Volt battery to positive and negative brush leads with 10 Amp fuse.
3. Note and record ammeter reading (battery voltage divided by rotor resistance).
4. Start engine; ammeter should remain stable (increasing = shorted rotor).
5. Check AC output across stator leads and compare to Table 7-1.

⚠ Sulfuric acid in batteries can cause severe injury or death

Tools: hydrometer

1. Remove filler caps and check electrolyte up to bottoms of filler holes.
2. Refill with distilled water or clean tap water; do not add fresh electrolyte.
3. Use battery hydrometer to check specific gravity of each cell.
4. Adjust gravity reading for electrolyte temperature.

⚠ Wash hands after any contact with engine oil

⚠ Do not pollute the environment; dispose of used oil properly

Tools: oil filter wrench, container

1. Drain oil warm by opening petcock right of dipstick; allow full drain then close.
2. Remove filter counterclockwise with oil filter wrench; discard properly.
3. Clean contact surface of oil filter adapter.
4. Apply light coat of fresh oil to filter rubber seal.
5. Thread filter to adapter until gasket contacts, hand-tighten one-half turn more.
6. Refill with 4 U.S. Quarts (3.8 L) of proper oil.
7. Start set, check for leaks at petcock and filter; stop and recheck level.

⚠ Do not over-tighten; may strip threads or alter electrode gap

Tools: spark plug socket with rubber insert, feeler gauge, gapping tool, torque wrench

1. Remove spark plug wires by grasping boot and turning slightly.
2. Clean dirt from around plug; remove plug with socket and rubber insert.
3. Wipe plug clean; file center electrode parallel to side electrode.
4. Check gap with feeler gauge; adjust with gapping tool.
5. Reinstall plug carefully, rotating clockwise until resistance felt.
6. Torque plug to 18-22 ft. lbs. (24-30 Nm) or 1/4 turn after hand-tight.
7. Clean boot connector and push boot firmly onto plug.

⚠ For storage of 2 months or more

1. Change oil and filter while engine still warm; run briefly to distribute clean oil.
2. Gasoline: drain carburetor bowl or run until empty; gas stabilizer permitted.
3. LP gas: with generator running, shut off LP supply and run until set stops.
4. Gasoline: remove fuel line at pump outlet to drain line, then reconnect.
5. Remove spark plugs, pour about 1 tablespoon engine oil into each hole.
6. Crank engine two or three revolutions to lubricate cylinders; reinstall plugs.
7. Clean exterior and apply light film of oil or silicone spray to unpainted metal.