TP-6053 7/04 45Section 9 Generator Disassembly/Reassembly
Section 9 Generator Disassembly/Reassembly
9.1 Disassembly
Disconnect all the external connections—battery cables
at the battery (negative (--) lead first), AC-output leads in
the controller, remote start panel at the controller P3
connector, water line at the seawater pump, fuel line at
the fuel pump filter inlet, and exhaust line at the mixing
elbow. Observe all the safety precautions listed at the
beginning of this manual during the disassembly/
reassembly procedures.
Note: Because this manual covers several models, the
procedure for disassembly may vary because of
product updates and the assembly variations.
Note: The voltage regulator is located in the controller
box. Remove the controller cover to service the
voltage regulator. Adjustments are possible
without removing the voltage regulator from the
controller.
1. Remove the end panel from the alternator end of
the generator set. See Figure 9-1.
2. Loosen the four screws and lift off the controller
cover.
3. Disconnect the P4 (22-pin) connector from J4.
4. Remove the bolt and disconnect the ground strap.
Note: It is possible to connect the output leads in
various positions for different volt
configurations. Mark leads 1, 2, 3, and 4 for
correct reconnection.
5. Disconnect the generator output leads 1, 2, 3, and
4 from the circuit breaker and neutral stud (L0).
6. Remove the four controller mount locknuts. See
Figure 9-2.
7. Lift the controller from the rubber mounts while
guiding the leads through the bottom hole of the
controller box.
8. Remove the tie wraps from the wire harness as
necessary. Disconnect the F1 connectors from the
resistor leads.
CD-250000-AJ
1
4
1. Controller cover
2. P4 (22-pin) connector
3. Ground strap
4. Generator end panel
3
2
Figure 9-1 Covers
558863
1
2
1. Controller mount locknut
2. Neutral stud (L0)
Figure 9-2 Controller Removal
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