Single-Phase Generator Reassembly - Kohler 15CCO Service Manual

1
1. Rotor Shaft
2. Wires
3. Slip Ring
Figure 8-16. Slip Ring Replacement on
Rotor Assembly
Allowable size of Slip Ring after being turned
down on a lathe:
Maximum Size Allowed
Minimum Size Allowed
Figure 8-17. Proper Slip Ring Size
Single-Phase Generator
Reassembly
1. Secure the drive disk to the rotor using eight bolts.
Torque bolts to 28 ft. lbs. (338 in. lbs.). Be sure to
follow the proper tightening sequence.
NOTE
Check condition of drive disks for flatness. If disks
are uneven or bent, then replace. Bent disks will
cause vibration and premature wear to end bearing
in end bracket.
8
1
6
1. Drive Disk
Figure 8-18. Drive Disk Tightening Sequence
8-6 Disassembly/Reassembly
2
3
5
A-225273-F
4. Terminals on Slip Ring
5. Ball Bearing
2.391 inches
2.360 inches
3
5
2
7
4
1
2. Position the rotor with the drive disk onto the engine
flywheel using eight bolts. Torque bolts to 14 ft. lbs.
(168 in. lbs.). Follow the tightening sequence as
shown above.
3. Attach the generator cooling fan using eight screws
and four spacers. Reassemble applying LoctiteR
#271 to screws.
4. Reposition the stator over the rotor and onto the
adapter lip. Be careful to avoid damaging the rotor.
When the stator is properly positioned, the stator
leads should be at the 12 o'clock position.
4
5. Route the stator leads through the opening in the
end bracket. Use a rubber mallet to secure the end
bracket onto the stator. Replace the overbolts
securing the end bracket and stator to the
generator adapter. Torque the overbolts to 25 ft.
lbs. (300 in. lbs.).
6. Pull the brush lead harness and stator leads
through the hole in the stator.
7. Use a hoist to raise the alternator end of the
generator set. Remove the wood block(s) from
underneath the alternator. Lower the generator set.
8. Replace
vibromounts to the stator mounting brackets.
9. Run the stator leads (1, 2, 3, 4, 55, B1, B2, 33, 44, 9,
20, and N) into the junction box through the hole in
the bottom of the box.
10. Position the junction box onto the stator mounting
bracket and secure using four mounting screws.
11. Inside the junction box, reconnect stator leads 1
and 4 to the line side of the circuit breaker and
reconnect stator leads 2 and 3 to the L0 ground
stud.
12. Reconnect the negative lead to the hazard ground
stud.
13. Reconnect lead 55 to the fuse holder.
14. Reconnect leads B1 and B2 battery charging
leads.
15. Reconnect the 6-pin connector (P10) to the voltage
regulator.
16. Reconnect leads 33 and 44.
17. Reconnect the white plastic connector containing
leads 9 and 20.
18. Reposition the junction box cover onto the junction
box and secure.
19. Reconnect the 22-pin controller harness (P4) to the
back of the controller.
the bolts securing the generator
TP-5606 6/02