7-9
DISASSEMBLY
WARNING
Accidental starting can cause se-
vere personal injury or death. Disconnect the
negative (−) cable(s) at the battery(ies) to pre-
vent the genset from starting.
WARNING
Accidentally dropping the genera-
tor can damage it and cause severe personal in-
jury or death. Use a hoist and straps of sufficient
capacity and attach them so that the load cannot
shift.
CAUTION
The generator drive plates will be
damaged if the rotor is used to support the sta-
tor during assembly or disassembly of the gen-
erator.
The generator is heavy. You will need a hoist of suffi-
cient capacity.
1. Disconnect all power output and remote control
connections and conduit at the generator. For
easier reconnections later, make sure each
lead is clearly marked.
2. Disconnect all engine harness connections
and grounding straps in the control box, all gen-
erator leads from connections in the output
box, and Connectors P1, P2 and P3 from the
genset controller. Disconnect connector P8
(some models) or disassemble the pins for
generator leads Q1, Q2, F1, F2, S1, S2 from
connector P3. Remove the control box, output
box and saddle as an assembly.
3. Hook the genset lifting eye with a hoist, remove
the throughbolts in the two generator mounts,
tip the generator end up slightly with the hoist
and block the flywheel housing to support the
engine while the generator is being serviced.
4. Cinch a strap around the middle of the genera-
tor stator and take up slack with the hoist.
5. On models with stator through bolts, scribe
lines before separating the end bell from the
stator and the stator from the flywheel housing
to register the parts for reassembly.
6. On models with stator through bolts, remove
the four nuts on the throughbolts and tap the
end bell free of the stator. On models with
flange bolts, remove the end bell and genera-
tor-to-engine flange bolts.
7. On models with stator through bolts, tap the
stator free of the flywheel housing, carefully
draw the stator straight back until it clears the
ends of the throughbolts and remove the
throughbolts. On models with flange bolts,
carefully draw the stator straight back until it
clears the end of the rotor.
8. Cinch a strap around the rotor and remove the
six disc-to-flywheel bolts (Figure 7-1). When
removed, cradle the rotor horizontally in wood-
en blocks to prevent damage to windings, lami-
nations and drive disc.
9. Use a gear puller to remove the rotor bearing or
exciter rotor (Figure 7-1).
Redistribution or publication of this document,
by any means, is strictly prohibited.
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