Generator
Assembly
Procedure
1. Install the stator in its housing
as
follows (see
Figure 8-6):
A.
Position
the
stator so the output leads
align with
the
access hole to control hous-
ing. Carefully lower the stator straight
down into
the
stator housing.
lA CAUTION! Careless handling
of
the
stator
can damage the Insulation on the
stator
windings. Do
not
brush the windings
against the housing as
It
Is lowered Into
housing,
and
take care
not
to drop
or
drag
the
stator
on
work area outside
of
stator
housing.
B.
Install
the
three stator clamps
and
cap screws.
C. Pull
the
stator leads into control box.
D.
Connect stator leads;
~
T1, T2,
T3
and T 4
to
terminal board TB1
$
01,
02,
F1
and F2 to voltage regulator
VR1
harness
J4
•
81
and
82
to
control printed circuit
board
harness
J1
E.
Rotate
the
stator/housing assembly
onto
a smooth, clean surface, resting
on
the
bell
shape
of
the housing (end bearing
face up).
2. Install the brush block assembly in the
stator
housing. Lift
the
brush wires and install
the
brush holding wire in
the
housing.
The
wire
holds
the brushes
off
the
slip rings during as-
sembly (see Figure 8-10).
3. Carefully place the rotor assembly
on
the
end
of
the
engine crankshaft, and replace
the
rotor
through-bolt. Tighten
the rotor through-bolt
only enough
to
hold the rotor in place.
lA CAUTION! Tightening the
rotor
through-
bolt
to the specified torque before the
sts~
tor
assembly Is Installed can result
rotor
shaft misalignment. Follow the
rf!:'com-
mended Installation procedures to
avoid
any
possibility
of
shaft misalignment.
4. Carefully plaDe the stator assembly straight
down
over
the
rotor and into position for as-
sembly
to
the
engine-to-generator adapter.
The rotor end-bearing should fit snugly into
the
bearing bore hole.
lA CAUTION I Careless handling
of
the
stator
can result In damage to the stator windings.
Do
not
brush the
stator
windings against
the
rotor
as
It
Is lowered Into position.
5.
Install
the
four nuts, locking washers, and
capscrews that secure
the
stator housing to
the engine-to-generator adapter. Tighten
the
cap screws to
the
specified torque. Note that
each locking
washer
is installed
under
the
capscrew head.
6. Tighten the rotor through-bolt
to
the
specified
torque.
7. Mount
the
starter
on
the
generator stator hous-
ing using capscrews, lock washers and nuts.
Tighten
to
the
specified torque.
8. Connect the leads
to
the
starter terminal stud.
9. Hold
the
drip pan in position
to
mount to
the
un-
derside
of
the set,
and
install the vibration-iso-
lator center screws. Note that
proper
flat
washers are
used
(large flat washers
at
each
isolator position). Tighten
the
center screws
to
the
specified torque.
1 0. Secure
the
ground strap to
the
drip tray using a
capscrew and
two
EIT locking washers. Note
that
the
ground strap is installed between
the
locking
washers
to
ensure a good electrical
connection.
11. Attach
the
lifting bolt (Figure 8-3) to
the
end
of
the
stator housing.
12. Attach a hoist
or
other
lifting device to
the
lifting
bolt. Carefully tilt
the
set
back
until it rests
on
the
drip tray.
Remove
the
lifting bolt
when
complete.
13. Connect plug/jack connections P1/J1 and
P3/J3
of
the
control printed circuit board. In-
stall
the
control panel assembly
on
generator
housing. Tighten
the
mounting screws.
14. Pull
the
brush leads outward and remove
the
wire holding
the
bn.Jshes
off
the
slip rings.
Make certain
that
the
brushes
are
centered
on
the
slip rings.
if
the
brushes are not centered,
loosen the brush block mounting screws and
adjust. Retighten
the
mountina screws when
complete.
~
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