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Home›Repair guides›Kohler›Brushless Models (RZ) — Reassembly

Kohler — Brushless Models (RZ) — Reassembly

Repair & overhaul · Generator

From a Kohler service manual covering: 10RMOY, 15RMOY, 15RMY, 15ROY, 17.5ROY, 22.5ROZ, 22.5RZ, 24ROZ, 32.5ROZ, 32.5RZ, 47.5ROZ. Check it applies to your exact model before use.

Applies to: Kohler 15RMY, Kohler 15ROY, Kohler 17.5ROY, Kohler 22.5ROZ, Kohler 22.5RZ, Kohler 24ROZ, Kohler 32.5ROZ, Kohler 32.5RZ, Kohler 47.5ROZ

Procedure

  1. Clean end bracket pilots and replace exciter field; replace J-bolts and tighten to 70 in. lbs. (.80 Kgm).
  2. Replace hardened washers and four long overbolts; turn end bracket face down on wood blocks.
  3. Attach lifting hooks and hoist stator over end bracket; lower onto clean end bracket pilot.
  4. Position generator adapter onto stator; bump snugly into place with a rubber mallet.
  5. Replace washers, four stator-to-end bracket and four stator-to-adapter attachment bolts (47.5 kW) or guide overbolts (all other models); hand tighten.
  6. Hoist generator assembly into horizontal position; torque all mounting bolts to 260 in. lbs. (2.99 Kgm).
  7. Hoist assembly back to vertical position on wood blocks.
  8. Fasten lifting eye and hoist hook to rotor flange; hoist rotor above stator and guide into position.
  9. Place generator fan on rotor; position drive discs on rotor flange and replace eight washers and bolts; torque to 50 ft. lbs. (6.92 Kgm).
  10. Hoist assembled generator level in line with studs on flywheel; guide drive discs over studs.
  11. Slide spacers over studs between drive discs and fan; replace nuts, do not final tighten.
  12. Align stator mounting with frame holes and adapter to flywheel housing; replace bolts and final tighten adapter.
  13. Final tighten fan and drive discs to flywheel.
  14. Replace generator fan guard; raise generator, remove wood blocks, replace vibro-mount bolts and ground strap.
  15. Remount speed sensor and set air gap to 0.020 in (0.508 mm); replace end panel and side panels.

Tools required

Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.

Specs & values

  • Exciter field J-bolt torque: 70 in. lbs. (.80 Kgm)
  • Mounting bolt torque: 260 in. lbs. (2.99 Kgm)
  • Drive disc bolt torque: 50 ft. lbs. (6.92 Kgm)
  • Speed sensor air gap: 0.020 in (0.508 mm)

Full service-parts list: Kohler 15RMY →, Kohler 15ROY →, Kohler 17.5ROY →, Kohler 22.5ROZ →, Kohler 22.5RZ →, Kohler 24ROZ →, Kohler 32.5ROZ →, Kohler 32.5RZ →, Kohler 47.5ROZ →

Source: Kohler service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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