Master TOC
TROUBLESHOOTING & REPAIR
MAIN GENERATOR FRAME REMOVAL
AND REPLACEMENT (continued)
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33.Using the rope sling and pry bars, carefully lift and “wiggle” the generator frame away from the engine and armature assembly. Be careful to support the generator frame as you remove it.
NOTE: The exciter frame is also removed with the main generator frame.
Reassembly: Refer to Figures F.13 - F.24 as needed.
1.Using the rope sling, carefully lift and “wiggle” the generator frame onto the engine and armature assembly. Be careful to support the generator frame as you position it.
2.Using the 9/16” wrench, install the bolts and lock washers mounting the generator frame to the engine. Using the 3/4” wrench, install the frame mounting bolts, nuts, and washers to the feet of the main generator. Check air gap
– min. .035” for main generator.
3.Using the 7/16” wrench, tighten the main gen- erator brush bracket clamping bolt. Note the position of the drill spot.
4.Install the eight brushes against the main commutator. Observe the positions you noted during disassembly.
5.Using the slot head screw driver, install the brush bracket
6.Carefully set the front panel assembly into position. Using the 3/8” nut driver, install the screw for the lower middle of the front panel. Using the 9/16” wrench, install the four bolts, nuts, and washers for the bottom of the front panel assembly. Then install the two bolts, nuts, and washers that hold the front panel assembly to the horizontal rails.
7.Using the 3/8” nut driver, connect the yellow wire from the oil pressure switch and the brown wire from the idler solenoid to the idler switch. Connect the blue wire and the black wire to the ammeter. See the Wiring Diagram.
8.Connect the white wire to the idler PC board. Connect the two red wires to the ignition switch. Connect the “H” lead to the START button switch. Connect the blue and brown main shunt leads at their quick disconnect splices. Connect the black lead between the idler PC board and the DC exciter.
9.Using the slot head screw driver, connect the red lead between the 115VDC receptacle and the DC exciter. Replace any cable ties cut during disassembly.
10.Using the slot head screw driver, install the choke control cable to the engine carburetor assembly, noting placement mark.
11.Using the 3/4” wrench, install the heavy lead to the positive output terminal and the copper strap lead and reed switch assembly to the negative output terminal.
12.Using the 1/2” wrench, install the five heavy flex leads to the selector switch as labeled during disassembly.
13.Carefully position the fuel tank to the mount- ing rails. Using the 9/16” wrench, install the four nuts, bolts, and washers holding the fuel tank assembly to the rails. Remove the plug from the fuel line and attach it to the fuel bowl.
14.Perform the DC Exciter Armature
Reassembly Procedure.
15.Carefully set the top and doors assembly into place. Install the “L” shaped door hooks. Using the 1/2” wrench, install the four nuts and bolts holding the case top and doors assembly to the welder frame. Install the rubber gasket to the top.
16.Using the 1/2” wrench, install the negative battery cable. Slide the battery mounting panel back into place and, using the 7/16” wrench, install the two bolts and washers that secure the panel.
