Cummins/Onan 4.5 CKM — Applying Anti-Seize Compound

For the Cummins/Onan 4.5 CKM.

Browse Cummins/Onan generators & specs →

Procedure

1. Coat tapered shaft with anti-seize compound, see Figure 8-1
2. Figure 8-14. Applying Anti-Seize Compound
3. Slide rotor onto tapered shaft and hand-tighten thru- bolt. Attach a strap wrench to rotor and torque thru- bolt to 50 ft. Ibs. (68 Nm), see Figure 8-15. es Figure 8-15. Torquing Rotor Thru-Bolt
4. Place stator over rotor and onto adapter lip. Be careful not to damage rotor. Position of stator should be with stator shell seam to the bottom and leads at the 2 o’clock position, see Figure 8-16. NOTE If a new stator (without center-tapped B1/B2 winding) is installed on a 120 Volt model, the circuit board B-239396 must be replaced with a C-239396. 8-4 Leads at the | 2 0’Clock Position SS - Seam to the Bottom Figure 8-16. Installing Stator
5. Slide stator leads through opening in end bracket and use a plastic hammer to install end bracket to stator. Align end bracket top edge parallel with exhaust manifold. Replace four over-bolts securing end bracket and stator to generator adapter, see Figure 8-17. Torque over-bolts to 260 in. Ibs. (7.9 Nm). Replace vibro-mount rubber caps and springs. Figure 8-17. Torqueing Over-Bolts
6. Place hoist hook into end bracket air vents and raise generator enough to remove wood block. Lower gen- erator onto vibro-mounts and remove hoist.
7. Slide engine wiring harness (plastic conduit) through end bracket grommet.
8. See Section 9. Wiring Diagrams” for proper wiring of generator set. Remount stator leads and P1-3 lead using end bracket ground (neutral) screw. If unitis a 120/240 Volt model, reconnect in-line connector of battery charging lead from circuit breaker to starter solenoid. If unit is a 120 Volt model, reconnect B1/B2 connector (if equipped) or add fully insulated push- on terminals to leads and connect B1 to P1-2 and B2 to P1-1. If unit is a 120/240 Volt model, reconnect B1/B2 connector (if equip
9. 11.
10. Figure 8-18. Removing Brush Retainer rings. Improper positioning will cause brushes to wear. Reconnect P1, P2 and P3 to controller circuit board. Mount controller panel to end bracket using two screws. See “Section 9. Wiring Diagrams” for reconnection of circuit breaker leads. Mount panel to end bracket using four screws. Install air cleaner assembly. Attach two screws and internal-external tooth lock washers to end bracket, install washer and lock nut to carburetor elbow stud, and attach br
11. \gor | | ie fe waL3W NOH yor te sal QO Or— : £} {9 TaNVd a1ON3Y YFTHOX + 2 YILYVLS AW1734 BUS, 2 asny divor 1uvLs = a 23 . 8 [ B3SNXIN 3 toy = 29, = OLAS, a unsssud ‘T SLNIOd QL 4 | —afsfif fift_— LWA 21 9-4 (10981S 79/1) P12OG HNIIND Q96EGET-D UUM HOA OFZ/OT! ‘WwesbeIG Buia V-@66222 N N\, \ \ \ ~ \\ fom aT TO TS, 0 91 (ae aot \ Pt 8) 18 HTT | \ T_T ih | LL. — oui lax rn 7“ gee a —_ | r0) il | i —" — tet f a escs ! | | ! leg pte | ee a | ral oh + 2 nT | fel | dWy | 1 \vory ! rho/! | | | | |
12. 98 sett — a Yor amo¢ Wn — mz, s S £ uaLUV1S 8 | aAltk LWA zt 9-15 Aejay YAS pue plkeog IINdUID 96E6E7-4 YUM (OBeqouulM) HOA OZE L) . DL wy a y + Quv0e YyaITOYULNOD od fae eee ae ee Se ee a a ee en S-2d ; - j <— ¥ Led ih] Hey t2d bal : : AY SSE 822 oe OY oavzm 1 vecot te af cal , a“ ™~, l, 2 ONIONIM YOLVLS NIV I s3aiy3s LiLW 7 ‘\ OOVE3NNIM / \ z 7 c ” ep bin O21 / \ Mae As LSOOBYIMOd / \ a a _een---- ~~ _ / \ a a corn (meu --- . st rv) toe pal { [ i . \ xav , 1 | 3S dAvS aaa ia ee re Si
13. 0) 1-1, 7-2 Stator oe eee e ete 1-1, 7-3 Rotor Disassembly/Reassembly ...............05. 8-3, 8-4 R@SIStANCE 2... cece ee tees 1-1, 7-2
14. 6-1, 7-2, 7-11 Troubleshooting .......... 2. e eee ees 6-1, 7-2 Safety Precautions 0.0... ec cece eee eee eee i Scheduled Mainten

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.