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Kohler — Generator Reassembly

For these Kohler models: 7.5A27, 7.5R23.

Applies to: Kohler 7.5A27, Kohler 7.5R23

Before you start

  • Improper brush-to-slip ring alignment may contribute to exciter voltage regulator failure and excessive ring wear.
  • If brush retainer wire is not removed, voltage regulator will be damaged when generator is started.
  • Do not remove or cut down spacer sleeve in vibromount assembly. Clearance is provided to protect against vibration damage.

Procedure

  1. Clean stub shaft taper and paint with copper-graphite or some other type of releasing agent.
  2. Slide stator into position making sure leads are at 12 o'clock position.
  3. Taking caution not to pinch any wires, position end bracket on stator. Bump snugly into place using a rubber mallet.
  4. Replace four long overbolts and torque to 75 in. ibs (8.5 Nm).
  5. Lift rotor assembly onto stub shaft and replace thru bolt. Torque thru bolt to 50 ft. ibs (68 Nm).
  6. If brush holder was removed, reinstall checking to see that brushes are properly centered on slip rings. Use a necessary amount of shims (Kohler No. 238248) to center brushes on slip rings. Remove retainer wire and reconnect brush leads to connector.
  7. Replace speed sensor. Turn rotor to position sensing lobe directly below speed sensor. Use a feeler gauge to set gap between sensor and lobe at 0.020 inch (0.51 mm).
  8. Reconnect stator leads 33 and 44 to the voltage regulator at quick disconnect.
  9. Remove blocks and return generator end to normal position.
  10. Reinstall generator support brackets and vibromounts.
  11. Lift controller back into position and replace three bolts on each side of the base.
  12. Replace generator end panel and slip ring-brush cover.

Tools required

  • rubber mallet
  • feeler gauge
  • shims (Kohler No. 238248)

Specs & torque values

  • Stub shaft taper: coat with copper-graphite or releasing agent
  • Rotor assembly thru bolt torque: 50 ft. ibs (68 Nm)
  • End bracket overbolts torque: 75 in. ibs (8.5 Nm)
  • Speed sensor gap: 0.020 inch (0.51 mm)

Source: manual:TP5043 Kohler Gen Service 7.5R27 7.5A27 7.5A23 Marine (08-1987).pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.