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Home›Repair guides›Kohler›Generator Reassembly - Brushless Models (RZ)

Kohler — Generator Reassembly - Brushless Models (RZ)

Repair & overhaul

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

Applies to: Kohler 15RMY

Before you start

  • Disconnect and remove starting batteries from work area to prevent fire hazard.

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 (all models except 47.5kW).
  3. Attach lifting hooks and hoist stator over end bracket; position stator mounting parallel with base of end bracket and lower onto clean pilot.
  4. Position generator adapter onto stator; make sure adapter base, stator mounting and end bracket base are parallel; bump adapter snugly with a rubber mallet.
  5. Replace washers, four stator-to-end bracket, and four stator-to-adapter attachment bolts (47.5kW). Guide overbolts into adapter and hand tighten (all other models).
  6. Hoist generator assembly into horizontal position. Torque all mounting bolts to 260 in. lbs. (2.99 Kgm).
  7. Hoist generator assembly (end bracket down) 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. Replace eight hardened washers and mounting bolts. Torque bolts 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.
  12. Replace nuts fastening drive discs and fan to flywheel; do not final tighten.
  13. Align stator mounting with holes in frame and adapter to flywheel housing mounting holes; replace bolts and final tighten adapter to flywheel housing.
  14. Final tighten fan and drive discs to flywheel. Insert bar through fan blades to turn and hold engine and rotor. Replace generator fan guard.
  15. Raise generator assembly; remove wood block(s) and return to normal position. Replace vibro-mount bolts and ground strap. Remount speed sensor and set air gap to 0.020 in. (0.508 mm). Replace end pane

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 →

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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