Kohler 5ERKM Service Manual page 38

Disassembly Procedure:
1. Place the start/stop switch in the STOP position.
2. Disconnect the generator set engine starting
battery, the negative (--) lead first.
3. Remove the controller cover.
4. Disconnect the P4 (22-pin) connector from J4.
5. Disconnect the controller ground strap (engine
side).
Note: It is possible to connect the output leads in
various positions for different voltage
configurations. Mark the leads for correct
reconnection.
6. Disconnect the generator output leads 1, 2, 3, and
4 from the circuit breaker and the neutral stud (L0).
7. Disconnect the P11 (FP and FN) and P10 (F1 and
F2) connectors.
8. Lift the controller from the rubber mounts while
guiding the leads through the bottom hole of the
controller box.
9. Remove the fuel pump and fuel inlet line from the
generator. See Figure 7-1.
10. Remove the coverplate.
11. Push the brushes into the holder. Secure the
brushes into position by sliding a retainer into the
brush keeping holes. Refer to Section 5.5.
12. Remove the brush holder and carefully slide the
leads out of the stator housing. See Figure 7-2.
13. Remove the generator side vibromount nuts.
28 Section 7 Generator Disassembly/Reassembly
14. Tilt the generator set up and brace it with a block of
wood. See Figure 7-3.
15. Remove the end bracket overbolts. Use a rubber
mallet to separate the end bracket from the stator
housing. See Figure 7-3.
16. Carefully remove the stator assembly from the
generator adaptor plate.
17. Loosen the rotor bolt, finger tighten, and back off
two turns.
18. Strike the bolt with a hammer until the rotor is freed
from the engine tapered drive shaft.
damage the bolt threads or the bolt head. See
Figure 7-4.
1
1. Controller
2. Fuel pump
Figure 7-1 Fuel Pump and Controller Removal
Do not
FV-277000
2
TP-6079 3/00