Kohler 4EF, Service Manual

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TP-5986 4/03 39 Section 9 Generator Disassembly/Reassembly
9.2 Collector Ring and Bearing
Replacement
1. Unsolder the collector ring leads from the collector
ring terminals.
2. Remove the collector rings with a three-jaw puller.
3. Remove the bearing with a three-jaw puller.
4. Press the new bearing onto the rotor shaft.
5. Align the collector ring keyway with the keyway on
the rotor shaft. See Figure 9-6.
6. Press the new collector rings onto the rotor shaft.
Note: The new collector rings must be turned
down to a finish of 32 micro inches using a
lathe and commutator stones. Turn down
the collector rings on the rotor shaft.
7. Solder the leads onto the collector ring terminals.
The connection is not to exceed 9.65 mm (0.38 in.)
beyond the collector rings. See Figure 9-6.
8. Test to ensure continuity at the collector rings.
9.3 Reassembly
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.
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 7.5.
8. Install the coverplate and torque the coverplate
bolts to 6.8 Nm (60 in. lbs.).
9. Install the sound shield enclosure.
10. Install the fuel line and fuel pump.
11. Reconnect the water inlet hose to the water pump.
12. Guide the leads from the stator through the bottom
opening of the controller. Secure the controller.
13. Reconnect the leads from the stator to the
controller using the reverse procedure of that listed
in Section 9.1.
Refer to Section 10, Wiring
Diagrams.
14. Connect the generator set starting battery, the
positive (+) lead first.
15. Test the generator operation.
Min. diameter mm (in.) 57.15 (2.250)
Max. finish 32 micro inches
Max. eccentricity mm (in.) 0.08 (0.003)
Max. out-of-round mm (in.) 0.01 (0.0002)
Figure 9-5 Collector Ring Dimensions
598695
1. Collector ring leads
2. Keyways
View A-A
A
A
1
2
90
°
.38 maximum
(as soldered)
Figure 9-6 Rotor Assembly