Section 9 Generator Disassembly/Reassembly; Disassembly - Kohler 5E Service Manual

9.1 Disassembly

Disconnect the external connections—battery cables at
the battery (negative (--) lead first), AC-output leads in
the controller, remote start panel at the controller P3
connector, water line at the seawater pump, fuel line at
the fuel pump filter inlet, and exhaust line at the mixing
elbow. Observe all of the safety precautions listed
during the disassembly/reassembly procedures.
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 (generator
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. Remove the fuel inlet hose.
9. Close the seacock and remove the water inlet hose
from the water pump.
10. Remove the sound shield enclosure, if equipped.
11. If the generator set is not equipped with a sound
shield enclosure, lift the controller from the rubber
mounts while guiding the leads through the bottom
opening of the controller box.
12. Remove the fuel pump and line from the generator.
13. Remove the alternator coverplate. See Figure 9-1.
TP-5986 4/03

Section 9 Generator Disassembly/Reassembly

1. Alternator end cover
2. Water pump
3. Vibromount nuts
Figure 9-1 Alternator end cover
14. Push the brushes into the holder. Secure the
brushes into position by sliding a retainer into the
brush keeping holes. Refer to Section 7.5.
15. Remove the brush holder and carefully pull the
leads out of the stator housing. See Figure 9-3.
16. Remove the generator side vibromount nuts. See
Figure 9-1.
17. Tilt the generator set up and brace it with a block of
wood. Figure 9-2.
1. Block of wood
Figure 9-2 Raising the Generator
Section 9 Generator Disassembly/Reassembly
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