Facts About Generators
GeneratorsDirectoryCompareRepairEnginesControllersPartsManufacturersGuides
Search models or part #
Home›Repair guides›Kohler›Installation Procedure — FRX LED Optic Board Dust Seal Kit GM94809-KP1

Kohler — Installation Procedure — FRX LED Optic Board Dust Seal Kit GM94809-KP1

Installation · FRX alternator LED optic board / activator board

From a Kohler service manual — check it applies to your exact model before use.

Browse Kohler generators & specs →

Before you start

  • Accidental starting can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.
  • Disabling the generator set: move master switch to OFF, disconnect power to battery charger, remove battery cables negative lead first (Decision-Maker 3+ and 550 Controllers).
  • Disabling the generator set: press generator set off/reset button, disconnect power to battery charger if equipped, remove battery cables negative lead first (Decision-Maker 3000, 3500, and 6000 Controllers).

Procedure

  1. Press generator set master control OFF/RESET. Disconnect power to battery charger if equipped and disconnect engine starting batteries, negative lead first.
  2. Open enclosure panels as needed. Remove junction box rear cover. Remove alternator (rodent) guard if used.
  3. Remove four screws and the LED optic board holder.
  4. Remove screw and LED optic board from the LED optic board holder.
  5. Place holder in a vise or stable surface and drill an 11/64 in. hole through the mounting boss.
  6. Remove three screws and the existing FRX activator board from the exciter armature. Do not reuse the existing board.
  7. Access back of FRX activator board and remove three elastic stop nuts from exciter armature leads AC1, AC2, AC3; note terminal positioning.
  8. Attach exciter armature leads AC1, AC2, AC3 to new FRX activator board GM94400 with elastic stop nuts; torque to 1.3 Nm (12 in. lb.).
  9. Position FRX activator leads around FRX spacer to prevent pinching; mount FRX activator board to FRX spacer with three screws; torque to 1.3 Nm (12 in. lb.).
  10. Install ball bearing X-758-19 to center retainer cup of the FRX activator board.
  11. Install FRX diode cover GC94111 in the inner race of the ball bearing.
  12. Reconnect the two-lead P6 connector at the LED optic board if previously disconnected.
  13. Mount LED optic board to holder with one screw; attach holder to end bracket with four screws; do not tighten at this time.
  14. Rotate threaded tang of FRX diode cover to align threaded hole with drilled hole; install screw M7985A-04016-20 and washer X-25-48; torque to 1.3 Nm (12 in. lb.).
  15. Final tighten four screws attaching LED optic board holder to end bracket; torque to 6.2 Nm (4.6 ft. lb.). Install fan guard and alternator (rodent) guard if equipped; replace junction box panels.

Tools required

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

Specs & values

  • Torque exciter armature leads to FRX activator board: 1.3 Nm (12 in. lb.)
  • Torque FRX activator board mounting screws: 1.3 Nm (12 in. lb.)
  • Torque pan head screw M7985A-04016-20 Amazon eBay with washer X-25-48 Amazon eBay: 1.3 Nm (12 in. lb.)
  • Torque LED optic board holder to end bracket screws: 6.2 Nm (4.6 ft. lb.)

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.

More Kohler repair guides →