Generator Disassembly and Assembly
Contents
1. GENERAC Ee Generator Disassembly and Assembly Service Manual A DANGER NOT INTENDED FOR USE IN CRITICAL LIFE SUPPORT APPLICATIONS ONLY QUALIFIED ELECTRICIANS OR CONTRACTORS SHOULD ATTEMPT INSTALLATION DEADLY EXHAUST FUMES OUTDOOR INSTALLATION ONLY This manual should remain with the unit This manual must be used in conjunction with the appropriate owner s manual WARNING California Proposition 65 Engine exhaust and some of its constituents are known to the state of California to cause cancer birth defects and other reproductive harm WARNING California Proposition 65 This product contains or emits chemicals known to the state of California to cause cancer birth defects and other reproductive harm ii Generator Service Manual Table of Contents Section 1 Disassembly and Assembly 1 1 Intended Purpose EPA DAY TATTY AE E A A E E ves wtunassudssubstviveatcedetuntintveatenut cuss duavivintwucenddedeseivounvubevestvavsuas 1 3 Disassembly Hints 1 3 1 Stator Disassembly 1 3 2 Rotor Disassembly 1 4 Assembly HINIS cccaadvasdvncteastesscevaravdunchactiautiensnanscsdeeusidddcensvavinietaxstecesauduauantdesudadeaudmeientavaians 1 4 1 Adapter Installation asnnssnnnennnnnnnunnnnennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nnmnnn n nnnnnnn tlie et eet teach te 1 4 2 Rotor and Fan Assembly 1 4 3 Stator Installation zsa a eA Re ee 1 4 4 Bearing Bracket Installation 1 4 5 Outlet C2. assembled to the stator in the following manner a The bracket web assembles the letter Y The vertical portion of the Y must be positioned at the bottom of the bracket b Align bracket stub shaft with the rotor bearing inner race bore Bearing bracket pilot must be aligned with the stator housing c Carefully and lightly tap on bracket CENTER ONLY until the bracket is seated on the stator shell Any pres sure or tapping on the bracket other than in the center can fracture the molded bearing support and slip ring assembly on the rotor 2 Secure with stator bolts The stator bolt holes must line up on the bearing bracket and adapter holes 3 If applicable inspect the brushes and replace them if worn to 1 2 inch or less 4 If applicable insert the brushes and tighten brush caps finger tight Be sure brushes work freely in holders 1 4 5 Outlet Cover Installation CAUTION If wires are not bundled and properly secured before the cover is installed the wires may come in contact with the rotor and be damaged When reinstalling cover ensure no wires are or will be pinched when the cover is installed The wires must be bundled and secured using wire ties as they were before disassembly 1 Verify all wires are placed properly and secured with wire ties to prevent damage 2 Install cover to bearing bracket using small screws NOTE If the duplex 120 volt receptacle is replaced observe the terminal on the ground side
3. gold color The duplex tab may have been split into individual receptacles by removal of this connecting tab If the tab has been removed the tab on the replacement receptacle must also be removed to ensure the outlets remain iso lated Generator Service Manual 3 Disassembly and Assembly This page intentionally left blank 4 Generator Service Manual GENERAC Part No MN2404 Rev A 01 28 2014 Printed in USA Generac Power Systems Inc Generac Power Systems Inc All rights reserved S45 W29290 Hwy 59 Specifications are subject to change without notice Waukesha WI 53189 No reproduction allowed in any form without prior written 1 888 GENERAC 1 888 436 3722 consent from Generac Power Systems Inc generac com
4. over Installation Generator Service Manual Table of Contents This page intentionally left blank iv Generator Service Manual Section 1 Disassembly and Assembly 1 1 Intended Purpose This quick guide is not intended to replace service training programs or information covered in specific product manu als It is merely a guide for an experienced individual who is already qualified and experienced in servicing generator sets This document is not meant to replace other service training or procedures 1 2 Overview The insert of Figure 1 1 shows the adapter face as viewed from the engine output shaft and how the rotor assembly attaches to the engine crankshaft The bottom illustration shows the disassembly assembly process Rotor Assembly Tapered Engine Crankshaft C Washer and Cap Screw Description Adapter 4 Cap Screws Fan Rotor Bearing Stator Bearing Bracket End Plate C Washer and Cap Screw Stator Bolts Olo N Oo AJOIN Figure 1 1 Typical Generator Assembly and Components NOTE Engine driven generator sets are subject to vibration Consequently all fasteners should employ a lock ing device Split type lock washers are generally suitable Generator Service Manual 1 Disassembly and Assembly 1 3 Disassembly Hints See Figure 1 1 During disassembly note the routing of the wire leads for the outlet cover and the method of securing
5. the leads Upon reassembly the leads must be reinstalled and secured as they were CAUTION Damage to the molded bearing support or slip ring assembly requires that the complete rotor assembly be replaced 1 3 1 Stator Disassembly The entire stator bearing bracket and outlet box may be removed as an assembly Open the control box cover and remove the collector ring brushes if applicable Remove the four stator bolts and fasteners used to secure the bearing bracket to the adapter Tap the bearing bracket at the stator bolt holes to release from the stator shell Now the stator assembly may be slid from the engine adapter casting by a gentle prying action between stator shell and engine adapter castings 1 3 2 Rotor Disassembly Loosen the rotor bolt a few turns using a thin wall 1 2 inch wrench Remove the C washer The rotor can be removed from the engine crankshaft rotor bolt does not have to be removed completely 1 4 Assembly Hints See Figure 1 1 NOTE Before assembly check adapter and engine shaft pilot surface fit Be sure all machined surfaces are clean free of burrs and damage 1 4 1 Adapter Installation Clean the engine shaft and pilot surface thoroughly Place the adapter on engine pilot surface There should be no observable left right up down movement If the adapter does not fit snug to the pilot replace the adapter Mount the adapter with four hex cap screws tightening in a diagonal fashion to pre
6. vent adapter warpage 9 Fe Ny 1 4 2 Rotor and Fan Assembly The rotor assembly mounts directly to the end of the tapered engine crankshaft NOTE Before assembly if the rotor stator or bearing bracket has sustained any mechanical damage replace all parts not just one damaged item 1 Install a 5 16 24 x 3 4 inch NF hex head cap screw into the end of the engine crankshaft Turn the cap screw approximately 3 8 inch into engine shaft The C washer will be installed after the rotor is on the crankshaft 2 Slip the rotor fully onto the engine crankshaft The cap screw extends through the rotor flange 3 Slide the C washer between the bolt head and the engine shaft see Figure 1 1 4 Tighten the cap screw with a thin wall 1 2 inch wrench NOTE Two bearing generators have permanently attached drive end castings Bearing replacement should only be performed by authorized personnel Consult Factory Service Department at 1 800 872 7697 CAUTION Damage to the molded bearing support or slip ring assembly requires that the complete rotor assembly be replaced 2 Generator Service Manual Disassembly and Assembly 1 4 3 Stator Installation 1 With stator shell seam down slip stator over the rotor onto engine adapter 2 Seat the rotor to the adapter using rawhide covered mallet 1 4 4 Bearing Bracket Installation CAUTION These steps must be followed exactly as written to prevent damage 1 The outboard bearing bracket must be
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