Section 8
ASSEMBLY
MAJOR DISASSEMBLY
ENCLOSURE/PANEL REMOVAL:
1.Remove enclosure door.
2.Remove the nine (9) enclosure roof bolts from the perimeter of the enclosure roof (a 10mm socket is required).
3.Remove six (6) enclosure side panel bolts from the outside perimeter Remove two (2) front & side enclosure panel bolts from the outside perimeter. Remove three (3) enclosure side panel bolts, located on the inside. Remove three (3) enclosure side panel nuts, two (2) on the top and one (1) on the side. Remove enclosure side panel (a 10mm socket is required).
4.Remove one (1) front & side panel enclosure nut located in the inside corner. Remove front & side enclosure panel (a 10mm socket is required).
5.Remove four (4) muffler bolts (a 13mm socket is required).
6.Loosen muffler clamp. Remove muffler (a 15mm wrench is required).
7.Remove three (3) side mounted muffler shield bolts. Remove two (2) muffler shield nuts located on the inside. Remove muf- fler shield (a 10mm socket is required).
8.Remove five (5) side and back enclosure panel bolts. Remove wing nut for control panel access. Remove three (3) upper con- trol panel bolts. Remove one (1) upper control panel nut (a 10mm socket is required). Move control panel
9.Remove red and black wires from the circuit breaker. Remove two (2) white and one (1) green wire from the ground lug (using a 10mm deep well socket).
10.Remove
11.Remove one (1) upper control panel nut. Remove one (1) lower panel nut in corner. Remove two (2) nuts behind upper control panel.
12.Remove six (6) air in duct base bolts from top of stator. Remove air in duct base (a 10mm socket is required).
STATOR REMOVAL:
1.Perform enclosure/panel removal steps
2.Remove six (6) air in duct base panel bolts from top of stator. Remove air in duct base (using a 10mm socket).
3.Remove four (4) standoff bolts from top of stator (a 13mm wrench is required).
4.Disconnect Wire 4 and Wire 0 from the brush holder assembly.
5.Remove two (2) brush holder assembly screws. Remove the brush holder assembly (a 7mm socket is required).
6.Remove Wire 11 and Wire 33 from the circuit breaker.
7.Remove Wire 66 and Wire 77 from the Battery Charge Rectifier (BCR).
8.Remove Wire 55 from the R1 resistor.
9.Remove Wire 11, Wire 22, and Wire 6 from the Voltage Regulator (VR).
10.Remove Wire 2 from the DPE circuit breaker (CB2).
11.Remove Wire 22 and Wire 44 from the ground lug.
12.Remove upper bearing carrier.
13.Remove stator.
ROTOR REMOVAL:
1.Perform Stator removal procedure steps
2.Remove carburetor air tube.
3.Remove fuel line.
4.Remove two (2) lower control panel nuts (a 10mm socket is required).
5.Unplug choke solenoid connector.
6.Disconnect Wire 0 and Wire 14 from bullet connectors to fuel solenoid. Disconnect Wire 0 and Wire 85 from Low Oil Pressure (LOS) and High Temperature (HT) switches. Remove positive and negative battery cables from remote box. Unplug Wires 13,16 & 18 from bullet connectors. Remove control panel.
7.Remove four (4) vibration mount nuts (using a 13mm socket).
8.Remove two safety nuts (using a 15 mm socket).
9.Lift generator out of bottom tray.
10.Remove seven (7) blower housing screws. Remove blower housing (using a 1/4” socket).
11.Remove two (2) side belt tensioner bolts. Remove belt (a 13mm socket is required).
12.Remove rotor pulley bolt. (14 mm socket) Use steering wheel puller to remove pulley (use M6 x 1 bolts for puller).
13.Lift rotor and bottom bearing carrier out. Press rotor/bearing from bottom bearing carrier.
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