Reassembly - Kohler 5ECD Service Manual

6.3 Reassembly

Note: See Section 1.6 and Appendix C for torque
specifications.
1. Apply antiseize compound to the tapered shaft of
the engine.
2. Align the rotor onto the engine shaft and secure
with the end drive fitting and rotor bolt. Torque the
rotor to 23.1 Nm (204 in. lbs.).
3. Carefully slide the stator assembly over the rotor.
4. Replace the end bracket o-ring. See Figure 6-6.
5. Install the end bracket and torque the overbolts to
13.6 Nm (120 in. lbs).
6. Feed the brush leads inside the stator housing up
through the opening. Secure the brush holder
using the original screws.
7. Remove the brush retainer and check the brush
alignment. See Section 5.6.
8. Install the coverplate and torque the coverplate
bolts to 6.8 Nm (60 in. lbs.).
9. Use the hoist to raise the alternator end. Remove
the wood block from under the locator plate. Lower
the generator set and install a bolt, a large washer,
two small washers, and a locknut on each
vibromount. Tighten the mounting bolts.
10. Install the SCR module and relay board.
TP-6391 9/08
11. Reinstall the support bracket to mount the junction
box. See Figure 4-1.
12. Install tie wraps to secure the wires as necessary.
13. Reconnect the leads to the circuit breaker, QCON1
to the F1 fuse, FP and FN leads, neutral stud (LO),
and ground stud (GRD) as marked during
disassembly. Refer to the wiring diagrams in
Section 7.
Note: Check the generator set nameplate to verify
the original voltage configuration.
14. Reinstall the ADC 2100.
15. Reconnect the P1, P15, and P16 connectors.
Connect the ground strap using bolt, washer, and
lock washer (install the lock washer against the
ground strap).
16. Reconnect all of the external connections—the
exhaust line to the catalyst assembly, the fuel line
to the fuel pump filter inlet, the water line to the
seawater pump, the remote interface connector,
the AC output leads, and the battery cables to the
battery (negative (--) lead last).
17. Verify that the generator set master switch is in the
OFF position.
18. Reconnect the engine starting battery, negative (--)
lead last.
19. Reconnect power to the battery charger, if
equipped.
Section 6 Generator Disassembly/Reassembly 63