8-3
SERVICING THE GENERATOR
WARNING
Accidental or remote starting can
cause severe personal injury or death. Before
removing a panel or access door, disconnect
the negative (–) cable at the battery to prevent
the engine from starting.
Stator Removal
1. Disconnect the generator leads inside the AC
outlet box and remove the top, front and left
side access doors and panels (Page 5-1).
2. Remove the second intake resonator chamber
(Page 8-4).
3. Remove the brush block (Figure 8-2).
CAUTION
The brushes can be damaged if
the brush block is not removed before re-
moving the end bell.
4. Remove the fan hub bolt and fan. (To keep the
rotor from turning while loosening the fan bolt,
hold the pulley bolt with a wrench.) To pull the
fan off the shaft taper, secure a three-point
wheel puller to the three holes in the fan hub
with M6 or 1/4 inch self-tapping screws.
5. Remove the end bell support bracket from the
engine bracket and the end bell (4 bolts).
6. Free the 8 generator leads from their connec-
tions and the clip on the side of the generator.
7. Scribe a line across the adapter, stator lamina-
tions and end bell to make realignment easier
during reassembly.
8. Block the stator so that it does not fall against
the rotor, and then remove the four generator
through bolts.
9. Pull the generator end bell straight out. Ex-
amine the bearing bore and replace the end bell
if it is scored or otherwise damaged by the bear-
ing.
10. Pull the stator assembly straight out, taking
care not to damage rotor or stator windings.
11. Block the rotor to support its hanging weight to
prevent damage to the adapter and bearing.
Stator Reassembly
Reassembly is the reverse of removal. Note the fol-
lowing:
1. Loosen the end bell support bracket bolts, if not
already removed, so that the bracket does not
interfere with proper stator and end bell align-
ment.
2. Align the stator and end bell with the line
scribed on them during disassembly.
Note:
Figure 8-1 shows a straight stator and the
through bolts lined up to pass through
round holes in the stator laminations. On
models with skewed stators the through
bolts must pass through slotted holes for
the end bell, stator and adapter to line up
properly.
3. Relubricate the bearing bore in the end bell with
molybdenum disulfide paste (Onan
PN 524-0118 or equivalent).
4. Make sure the wave washer and O-ring are in
place in the bearing bore.
5. Torque the stator through bolts and end bell
bracket bolts to 8 lb-ft (11 N-m) and the fan hub
bolt to 45 lb-ft (61 N-m). (To keep the rotor from
turning while tightening the fan bolt, hold the
pulley bolt with a wrench.)
6. Make sure to tie the generator leads to the clip
on the side of the generator.
Rotor
To remove the rotor, remove the stator and then the
drive pulley (Page 7-2) and pull the rotor straight out
to the front. When reassembling, lubricate the bear-
ing bores in the end bell and adapter with molybde-
num disulfide paste (Onan PN 524-0118 or equiva-
lent). Make sure the wave washer is in place in the
end bell and that the O–rings are in place in the
bearing bore groves in both ends.
Press each bearing on up to its shaft shoulder using
a bench press.
CAUTION
Apply force only to the bearing in-
ner race to avoid damage to the bearing.
Redistribution or publication of this document,
by any means, is strictly prohibited.
Summary of Contents for MDKBH Series
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