Kohler 100 RZ Generator Set

Tools: hoist, lifting eyes, wood blocks, wrenches

1. Disconnect controller-to-engine and engine-to-generator harnesses and wiring.
2. Remove bolts from generator vibro-mounts.
3. Suspend generator at both ends with hooks in lifting eyes.
4. Place wood blocks under flywheel housing; lower generator end onto blocks.
5. Remove fan guard; remove bolts holding adapter to flywheel housing.
6. Remove nuts and spacers holding drive discs to flywheel.
7. Work drive discs over studs to separate generator from engine.
8. Set generator on floor horizontally; remove drive discs and fan.

Tools: hoist, torque wrench, wrenches

1. Install new tolerance ring in end bracket.
2. Suspend rotor over generator; lower rotor field into stator.
3. Align rotor bearing into end bracket tolerance ring.
4. Place fan over rotor flange and torque bolts.
5. Fasten drive discs to rotor shaft and torque bolts.
6. Attach hoist to end bracket and adapter eye; raise generator horizontally.
7. Align studs with drive discs; install spacers; fasten adapter to flywheel housing.
8. Install fan guard; replace LED board, speed sensor, junction box, controller; reconnect systems.

⚠ Unit starts without notice; turn Master Switch off and remove battery cables.

⚠ Electrical shock from battery; remove jewelry.

⚠ Hot piping; allow unit to cool.

Tools: battery tools, fuel containers

1. Disconnect starting batteries, negative lead first; remove from work area.
2. Disconnect AC accessories: battery charger, block heater, fuel transfer pump.
3. Shut off fuel supply and drain fuel into proper containers.
4. Ventilate work area to clear fumes.
5. Disconnect fuel, cooling, and exhaust systems as necessary to tilt generator.
6. Disconnect output leads or load circuit cables at generator.
7. Check generator weight on nameplate; verify lifting equipment rated.

Tools: hoist, lifting eye, screwdriver, wire stripper, crimp tool, torque wrench

1. Fasten lifting eye and hoist hook to rotor flange.
2. Hoist rotor carefully to avoid damaging exciter field magnets.
3. Remove screws securing photo transistor board; retain screws.
4. Install new photo transistor board; route lead through rotor shaft.
5. Attach board, insulator, washers, and actuator cup with retained screws.
6. Cut excess lead; strip gray jacket 2-3 in.; strip 1/4 in. insulation; crimp terminals.
7. Secure leads to rotor shaft with tie wrap.
8. Connect red to F+ stud, green to G stud, white to AC, black to other AC.