TT-1711 6/17a

INSTALLATION INSTRUCTIONS

Original Issue Date: 12/16

Model: 20--200 kW with Fast-Responser X Alternator
Market: Industrial, Residential/Commercial, and Marine
Subject: FRX LED Optic Board Dust Seal Kit GM101820-KP1-QS
Introduction Special Tools Needed
D Drill, 1/4 in. chuck
Kohler Co. has released a new option for the FRX series
alternator. The GM101820-KP1-QS dust seal kit is D 11/64 in. drill bit
designed to reduce maintenance of the LED/photo D Torque wrench capable of 1.3--6.2 Nm (12 in. lbs. to
transistor boards when generator sets are used in dusty 4.6 ft. lbs.)
conditions. The kit provides a flexible tube to seal the D Torque wrench capable of 194 Nm (143 ft. lbs.)
space between the LED board and photo transistor
board reducing the formation of dirt and/or dust on the Safety Precautions
optical devices thereby increasing maintenance
intervals. See Figure 1. WARNING
Refer to the Fast-Responser X Service Manual
TP-6783 as needed for additional disassembly
information.

Accidental starting.
Can cause severe injury or death.

1 Disconnect the battery cables before

working on the generator set.
2 Remove the negative (--) lead first
when disconnecting the battery.
3 Reconnect the negative (--) lead last
when reconnecting the battery.

Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the
4
generator set as follows: (1) Move the generator set master
5
switch to the OFF position. (2) Disconnect the power to the
battery charger. (3) Remove the battery cables, negative (--)
GM94809-
lead first. Reconnect the negative (--) lead last when
reconnecting the battery. Follow these precautions to prevent
1. FRX activator board
starting of the generator set by an automatic transfer switch,
2. Ball bearing remote start/stop switch, or engine start command from a
3. Diode cover remote computer.
4. Washer, plain (Decision-Makerr 3+ and 550 Controllers)
5. Screw, pan head
Disabling the generator set. Accidental starting can
Figure 1 FRX Diode Circuit Board Dust Seal Kit cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.
(Decision-Makerr 3000, 3500, and 6000 Controllers)
Installation Procedure
Note: Read all safety precautions at the beginning of
this publication before performing any work on
the generator set.
1. Remove the generator set from service.
1.1 Press the generator set master control
OFF/RESET button or move the generator set
master switch to the OFF position.
1.2 Disconnect the power to the battery charger, if
equipped.
1 SB-742
1.3 Disconnect the generator set engine starting 2
1. LED optic board
battery(ies), negative (--) lead first. 2. Screw

2. Access the alternator end of the Figure 3 LED Optic Board and Holder
generator set.
2.1 Open the enclosure panels as needed.

2.2 Remove the junction box rear cover.

2.3 Remove the alternator (rodent) guard, if used.

3. Remove the existing components.

3.1 Remove the 4 screws and the LED optic board
holder. See Figure 2.

3.2 Remove the screw and LED optic board from the 1
LED optic board holder. See Figure 3.

3.3 Place the LED optic board holder in a vise or on a

stable surface and drill an 11/64 in. hole through the SB-742
mounting boss shown in Figure 4 and Figure 5. 1. Mounting boss (drill through using 11/64 in. drill bit)

Figure 4 Drill Hole Through Mounting Boss

SB-742
1. LED optic board holder
2. Screws (qty. 4)
SB-742
1
Figure 2 Removing LED Optic Board Holder 1. Hole in FRX activator board holder (highlighted for clarity)

Figure 5 Hole in FRX Activator Board Holder

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3.4 For Units Before Alternator Serial Number
96779: Remove the 3 screws and the existing
FRX activator board from the exciter armature.
See Figure 6. The existing FRX activator board
and 3 screws will not be reused.

For Units After Alternator Serial Number

96779: Remove the 5 nuts, the thread-forming
screw, and the FRX activator board from the
exciter armature. The existing FRX activator
board, 5 nuts, and thread-forming screw will not be
reused. Proceed to Step 4.5.

SB-742

Figure 8 Removing Leads from the FRX Activator

Board

3.6 For Units Before Alternator Serial Number

96779: Remove the spacer by removing the
3 screws. See Figure 9. The existing spacer and
3 screws will not be reused. Remove the bow
washer and bolt only when changing the
armature.

1 2 SB-742 1
1. FRX activator board
2. Screws (qty. 3)

Figure 6 Removing the FRX Activator Board

2
3.5 For Units Before Alternator Serial Number
96779: Access the back of the FRX activator
board and disconnect the exciter armature leads 3
(AC1, AC2, and AC3) and rotor assembly leads
(F1 and F2) by removing the 5 elastic stop nuts.
Note the lead terminals and their positioning on
the FRX activator board silkscreen. See Figure 7 5
and Figure 8.
GC70113B-

7 1 4

6 NOTE: Remove items 2 and 3 only when changing the armature.

1. Exciter armature
2 2. Bow washer (position washer with convex side outward)
5 3. Bolt
4. Three screws
5. Spacer

4
Figure 9 Spacer Removal

3
SB-742

1. Exciter armature lead AC2 5. Rotor assembly lead FN

2. Exciter armature lead AC1 6. Exciter armature lead AC3
3. FRX activator board 7. Silkscreen positioning box
4. Rotor assembly lead FP

Figure 7 FRX Activator Board

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4. Install the kit components.
4.1 For Units Before Alternator Serial Number
96779: Mount the new spacer (GM98936) to the
exciter armature using 6 thread-forming Torx head
screws (M7500CE-05020-85). See Figure 10
and Figure 13.

Note: Orient the non-electrical connection mounting

hole to the mounting hole above the keyway. See
Figure 12.

Side View

Figure 11 Routing of Leads

1 No electrical connection
F2
(F--) AC1

F1
(F+) AC2
AC3
1. Thread-forming Torx head screws (M7500CE-05020-85 qty. 6)
1
Figure 10 Spacer (GM98936) Installation

4.2 For Units Before Alternator Serial Number

96779: Route the exciter armature and rotor leads
(AC1, AC2, AC3, F1, and F2) around the outer
diameter of the spacer to the inside to eliminate
slack. See Figure 11 and Figure 12.

Note: Lead connection locations are identified on the

spacer and in Figure 12.

Note: Secure excess lead length before attaching

terminals. 2
1. Route leads around spacer OD to inside to eliminate
4.3 For Units Before Alternator Serial Number slack (leads not shown).
96779: Use 5 terminals (X-283-58) and 5 stainless 2. Terminals (X-283-58 qty. 5) and stainless steel hex nuts
steel hex nuts (M934-04-SS) to connect leads (M934-04-SS).
Terminal barrels located down into spacer pockets.
AC1, AC2, AC3, F1, and F2 to the spacer studs.
Torque to 1.3 Nm (12 in. lbs.). Locate the terminal Figure 12 Spacer (GM98936) Connections
barrels down inside the spacer pockets. See
Figure 12 and Figure 13. 4.5 Secure the activator board (GM98939-2) to the
studs on the spacer by using 5 stainless steel
4.4 For Units Before Alternator Serial Number elastic stop hex nuts (M985-04-SS) and a
96779: If the armature was changed, secure the thread-forming screw (X-6071-8). Torque to
new exciter armature by reusing the existing bolt 1.3 Nm (12 in. lbs.). See Figure 13 and Figure 14.
and bow washer. See Figure 9. Torque to 194 Nm
(143 ft. lbs.).

4 TT-1711 6/17
 Side View
5
2

3
6

GC79429-43

Listed in order of assembly:

1. Spacer (GM98936) 5. Activator board (GM98939-1)
2. Thread--forming Torx head screw (M7500CE-05020-85 qty. 6) 6. Thread-forming screw (X-6071-8)
3. Terminal (X-283-58 qty. 5), not shown 7. Stainless steel nylock nut (M985-04-SS qty. 5)
4. Stainless steel hex nut (M934-04-SS qty. 5)

Figure 13 Components Shown in Order of Assembly

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 1 4.10 Attach the LED optic board holder to the end
bracket using four screws. Do not tighten at this
time.
2
4.11 Rotate the threaded tang of the FRX diode cover
as necessary to align the threaded hole with the
drilled hole in the FRX activator board bracket.
Install the pan head screw M7985A-04020-20 and
plain washer X-25-48 and torque to 1.3 Nm
(12 in. lb.). See Figure 16 and Figure 17.

4.12 Final tighten the 4 screws attaching the LED optic

board holder to the end bracket and torque to
1. Thread-forming screw (X-6071-8)
6.2 Nm (4.6 ft. lb.).
2. Stainless steel nuts (M985-04-SS qty. 5)
4.13 Install the alternator (rodent) guard to the end
Figure 14 Activator Board bracket (if equipped).
4.6 Install the ball bearing (X-758-19) to the center 4.14 Replace the junction box panels.
retainer cup of the FRX activator board and secure
using the spiral retaining spring (GM98940). See
Figure 15. 5. Restore the generator set to service.
5.1 Check that the generator set OFF.

5.2 Reconnect the generator set engine starting

battery, negative (--) lead last.

5.3 Reconnect power to the battery charger, if

equipped.

SB-742

Figure 15 Mounting FRX Activator Board

4.7 Install FRX diode cover GC94111 in the inner race

of the ball bearing. See Figure 16.
SB-742
4.8 Reconnect the two-lead P6 connector at the LED 1 2
optic board (if previously disconnected). 1. FRX diode cover
2. Threaded tang
4.9 Mount the LED optic board to the LED optic board
Figure 16 Installing the FRX Diode Cover
holder using one screw.

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 Parts List
FRX LED Optic Board Dust Seal Kit
GM101820-KP1-QS
Kit: GM101820-KP1-QS
Qty. Description Part Number
1 PCB activator board GM98939-2
1 FRX diode cover GC94111
1 Ball bearing X-758-19
1 Screw, pan head M7985A-04020-20
1 Washer, plain X-25-48
1 Spiral retaining ring GM98940
1 Spacer GM98936
6 Screw, thread forming Torx head M7500CE-05020-85

2 SB-742 5 Terminal X-283-58

1
1. FRX activator board holder 5 Hex nuts, stainless steel M934-04-SS
2. Screw and washer attached to the FRX diode cover 5 Nylock nuts, stainless steel M985-04-SS
threaded tang
1 Screw, thread forming X-6071-8
Figure 17 Installing the FRX Activator Board Holder

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KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems
Phone 920-457-4441, Fax 920-459-1646 Asia Pacific Headquarters
For the nearest sales and service outlet in the 7 Jurong Pier Road
US and Canada, phone 1-800-544-2444 Singapore 619159
KOHLERPower.com Phone (65) 6264-6422, Fax (65) 6264-6455

Availability is subject to change without notice. Kohler Co. reserves the

right to change the design or specifications without notice and without any
obligation or liability whatsoever. Contact your local Kohlerr generator
set distributor for availability.
 2016 and 2017 by Kohler Co. All rights reserved.

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