9-7
Generator Assembly
Use the following procedures to assemble the gen-
erator:
1. Position the stator so the output connector
aligns with the opening in the stator housing.
Carefully slide the stator into the generator
housing. If necessary the stator can be lightly
tapped on the laminations so that the stator is
seated into the housing. Insert and tighten the
two stator through bolts.
CAUTION
Careless handling of the stator
can damage the insulation on the stator
windings. Do not brush windings against
the housing or strike windings during
installation.
2. Align the pin in the rotor shaft with the notch in
the crankshaft and slide the rotor onto the
crankshaft. Make sure that the rotor is seated.
3. Plug in both stator wire connectors.
4. Prepare the endbell for installation. Lubricate
the o-ring on the bearing. Verify that the
brushes are held inside the holder with a piece
of wire and that the brush block is loose. See
Figure 9-4 on Page 9-6. Install the endbell
onto the rotor bearing and secure to the stator
housing with the endbell mounting screws.
CAUTION
The brushes will be damaged
during assembly if not held off the slip rings
and the brush block is loose enough to
clear the bearing. Make certain wire is in
place before installing the generator end-
bell.
5. Center the brush block on the slip rings and
tighten the mounting screws. Remove the
piece of wire holding the brushes off the slip
rings. Connect the F2 lead wire to the outer
brush terminal (near bearing) and the F1 lead
wire to the inner brush terminal. Connect the
magneto assembly wires.
6. Install the fan hub assembly onto the rotor shaft
and align the key slot on the fan hub with the
key slot in the rotor shaft. Install the key into the
key slot. Install the rotor through bolt and wash-
er. Verify alignment of the rotor shaft and the
fan hub, then secure the fan hub assembly and
tighten the rotor through bolt to the specified
torque.
7. Spec A: Assemble the starter bracket to the
starter. Install the scroll housing.
Begin Spec B: Install the air housing assembly.
8. Remove the wooden block from under the sta-
tor housing and slowly lower the genset.
9. Install the muffler assembly and make sure
new gaskets are used. Install the generator
and engine to base mounting bolts (use anti-
seize lubricant on bolt threads). Secure all
hardware to the specified torque.
10. Reconnect the load leads, the fuel pump leads,
and ground terminal block or connections.
Install the control panel on Spec A. Install the
voltage regulator and control assembly. On Be-
gin Spec B models: reconnect the start sole-
noid leads and the P4 and J1 connectors.
11. Inspect the assembly, check all electrical and
mechanical connections for correct fit and loca-
tion. Place the enclosure cover on the genset
and secure with the side mounting screws.
(Begin Spec B, 50 Hz models: Connect the
leads to the battery charger assembly mounted
to the left side of the housing.)
12. Install the genset in the vehicle and securely
fasten all mounting screws and hardware. Con-
nect the fuel line, exhaust system and electrical
systems in reverse order of disassembly. Refer
to
Set Removal Guidelines
on Page 5-2 for the
recommended genset removal procedures.
13. Fill the crankcase with oil of the recommended
classification and viscosity (refer to the Opera-
tor’s Manual).
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