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Remove Isolator Mounts (if required)
NOTE: Removal of isolator mounts is not necessary for
servicing engine or alternator.
Remove nuts and washers securing isolator mounts, and
remove isolator mounts.
PRO 5.4 DES Alternator
A
End Cover
E
Front Cover Shield
I
Rotor
Remove Stator
NOTE: Take care not to damage stator coil and rotor
coil when removing/installing them.
NOTE: Place stator core side down. Do not set stator on
coil end. Coils may be damaged.
NOTE: Stator is heavy; be prepared to handle weight to
maneuver for inspection and service.
NOTE: If disassembling stator assembly, draw a line or
mark on front cover, stator cover and rear cover
for proper alignment in reassembly.
1. Remove through bolt from rotor.
2. Loosen alternator mount on rear cover and remove.
3. Remove screws securing front cover to engine
adapter. Use a gear puller to remove stator
assembly. Stator assembly will be heavy.
4. Replace through bolt into rotor, but do not tighten.
38 690 01 Rev. --
L
E
D
E
F
B
Rear Cover
F
Engine Adapter
J
Bearing
KohlerPower.com
Disassembly/Inspection and Service
B
C
H
G
C
Stator
G
Fan
K
Through Bolt
5. Stator assembly can be disassembled further:
a. Place stator assembly vertically with front cover
down on work surface.
b. Remove screws from rear cover and remove rear
cover, stator cover and stator.
6. Inspect parts for cracks. Replace if cracked.
Remove Rotor
1. Place a wooden block or similar material under rotor
to support weight as rotor is removed.
2. With a rubber mallet, tap rotor a few times. Rotor
should break free from engine shaft. Remove
through bolt and remove rotor.
3. Inspect fan and rotor for cracks. Replace if cracked.
A
K
J
I
D
Front Cover
H
Stator Cover
L
Stator Assembly
17
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