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Cummins/Onan 4.5 CKM — Remove aircleaner assembly by removing two screws

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Procedure

  1. Remove aircleaner assembly by removing two screws and internal-external tooth lock washers at end bracket, lock nut and washer at carburetor elbow, and breather hose at air cleaner.
  2. Remove four screws to release end bracket panel, see Figure 8-1. With the end bracket panel removed, the voltage regulator is now accessible. To remove con- troller panel, rernove two screws and unplug P1, Pe, and P3, see Figure 8-2. Remove circuit breaker leads (Figure 8-3) and remove end bracket panel. Figure 8-1. Removing End Bracket Panel Figure 8-2. Removing Controller Harness Plugs Figure 8-3. Removing Circuit Breaker Leads
  3. Lift the brushes by the leads and lock in this position by inserting a retainer wire. See Figure 8-4. Figure 8-4. Inserting Brush Retainer
  4. Cut cable tie(s) securing plastic conduit to over-bolt. Disconnectieads 33, 44, 55, and 66 from voltage regu- lator. Unscrew cable tie at upper right-hand corner of voltage regulator and cut cable tie to release leads. Disconnect B1/B2 connector (if equipped) or cut leads B1 and B2 at insulinks and add fully insulated push-on terminals to 120 Volt models. If unit is a 120/240 Volt model, disconnect B1/B2 connector (if equipped), or disconnect leads from P1 connector at battery charging rectifier
  5. Remove ground strap at vibro-mount, see Figure 8-6. Remove vibro - mount nuts, lock washers, flat washers, and bolts from end bracket, see Figure 8-7.
  6. Slide engine wiring harness (plastic conduit) from end bracket grommet.
  7. Place hoist hook into end bracket air vents and raise generator end, see Figure 8-8. Place a wood block 8-2 Figure 8-8. Hoisting Generator End under generator adapter and lower generator until adapter is supported by block.
  8. Disassemble vibro-mount rubber caps and springs to remove four over-bolts from end bracket, see Figure 8-9.
  9. Use a plastic hammer to remove end bracket from stator. See Figure 8-10. Figure 8-10. Removing End Bracket with Plastic Mallet
  10. Use a pry bar or large screwdriver to loosen stator from generator adapter, see Figure 8-11. Be careful not to damage rotor while removing stator. Note posi- tion of stator leads before removing stator.
  11. Loosen thru-boit 2-3 turns leaving a 1/8 inch (3 mm) gap betweén bolt and rotor (Figure 8-12) and then strike thru-bolt head with a lead hammer using a medium force blow to loasen rotor, see Figure 8-13.
  12. Remove thru-bolt and slide rotor from tapered shaft. Acaution Do not attempt to remove rotor by blocking engine cooling fan and turning rotor with any kind of wrench. Damage to fan blades and rotor may result. Figure 8-12. Loosening Thru-Boit Figure 8-13. Striking Thru-Bolt 8-3

Source: manual:TP5206 Kohler Gen Service 4.5CKM (06-1990).pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.