1. Remove the PMG, refer to Permanent Magnet PMG Removal, earlier this section.
2. Remove the air inlet and discharge panels and access covers from control housing and gener-ator (see Figure 6-7 or 6-8).
3. Disconnect all load wires from the reconnec-tion terminal block assembly (see Figure 6-9).
If equipped with the circuit breaker option, dis-connect load wires from circuit breaker. Check that all leads are labeled to ease reassembly.
4. Disconnect the remote control wiring and con-duit from the accessory box. For reconnections later, make sure each wire is clearly marked to indicate the correct terminal.
5. Disconnect the engine harness connectors and remove harness assembly from the control housing:
• P4 and P5 from the back side of the control panel box.
• PMG2 through PMG4, F1 and F2 genera-tor leads located inside the control hous-ing assembly.
• P6 (Governor Output Module), P7 and P10 (Voltage Regulator OUtput Module) and J12 (from P12 of the rail assembly), lo-cated inside the accessory box.
6. Use a hoist or similar lifting device to support the control housing assembly (see Figure 6-9).
WARNING To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.
7. HC4−7 Control Housing Removal:
a. Loosen the fasteners that secure the con-trol housing side and bottom panels to generator. Make sure that hoisting device is controlling weight of control housing as-sembly.
b. Remove control housing fasteners, and remove the control housing assembly from the generator. Replace panel fasten-ers to their respectable positions for safe keeping, and tighten finger-tight.
c. Remove control housing mounting brack-ets from both sides of generator, and as-semble lifting eyes to generator.
8. P7 Control Housing Removal:
a. Loosen the fasteners that secure the con-trol housing side panels to generator.
Make sure that hoisting device is control-ling weight of control housing assembly.
b. Remove control housing fasteners, and remove the control housing assembly from the generator. Replace panel fasten-ers to their respectable positions for safe keeping, and tighten finger-tight.
PLACE SLING STRAPS THROUGH HOUSING (P7 OR HC4−7 HOUSING)
RECONNECTION TERMINALS
ACCESSORY BOX
FIGURE 6-9. REMOVING CONTROL HOUSING
9. Remove as necessary, air intake components to engine that may interfere with disassembly and reassembly of generator. Cover intake opening to prevent debris from entering engine induction system.
CAUTION Do not use fan blade to bar over engine. That can damage blades and cause property damage and personal injury.
10. Crank or bar the engine/generator to position the rotor such that a full pole face is at the bot-tom of the main stator core. Proper positioning can be viewed through the generator access openings. Refer to engine service manual for proper cranking or barring procedure.
To remove the stator and rotor at the same time, refer to step 29. To remove the stator and rotor individual-ly, continue with step 11.
11. Remove the four bolts retaining the bearing cartridge housing in the endbracket (outer four bolts).
12. Remove the eight bolts holding the endbracket to the generator housing.
13. Insert two bolts (M10) in the two holes provided for “jacking” purposes, on the endbracket cen-ter line. Screw bolts in until endbracket spigot is clear of locating recess.
14. Carefully tap the whole assembly off the bear-ing cartridge housbear-ing, ensurbear-ing the endbracket is supported to prevent the exciter stator from damaging the windings on the exciter rotor.
WARNING To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.
15. The exciter stator is now accessible for inspec-tion and removal from endbracket/engine adaptor.
16. The end bearing can now be removed if re-quired. Refer to Bearing Inspection/Removal/
Replacement in this section.
17. Remove the fasteners from the two generator mounting feet brackets.
18. Attach cables of lifting device to generator lift-ing points (Figures 6-10 or 6-11).
GENERATOR LIFTING POSITIONS
MOUNTING FEET BRACKETS
FIGURE 6-10. HC4−7 GENERATOR LIFTING POSITIONS
FIGURE 6-11. P7 LIFTING POSITION
19. Using an adequate lifting device, lift the gener-ator (at lifting eyes provided, and main stgener-ator housing) until the mounting feet brackets are clear of the frame member (see Figure 6-12 or 6-13).
20. If the engine does not have chassis mounts at generator end, block the rear of the engine in place by supporting the flywheel housing. A length of steel channel and wooden blocking is required to support the rear of the engine.
Place the channel and blocking under the
fly-wheel housing. Lower the generator until most of the set weight is supported by the blocking (see Figure 6-12).
21. Disconnect the grounding strap from the fly-wheel housing.
22. Using a forklift, position a lifting bar of the forklift (inside and inline with the generator) under the rotor shaft. Lift the rotor shaft slightly so that ro-tor is not resting on inside of staro-tor assembly.
See Figure 6-12 or 6-13.
STATOR ASSEMBLY
LIFT
ROTOR ASSEMBLY
LIFT
STATOR
ASSEMBLY ROTOR
ASSEMBLY USE FORKLIFT OR
OTHER ADEQUATE LIFTING DEVICE TO SLIGHTLY LIFT ROTOR
SHAFT UNTIL ROTOR CAN BE SUPPORTED
BY HOIST/SLING.
BLOCKING UNDER ENGINE FLYWHEEL
HOUSING
FIGURE 6-12. REMOVING HC4−7 STATOR ASSEMBLY
STATOR ASSEMBLY
LIFT
ROTOR ASSEMBLY
LIFT
STATOR ASSEMBLY
ROTOR ASSEMBLY USE FORKLIFT OR
OTHER ADEQUATE LIFTING DEVICE TO SLIGHTLY LIFT ROTOR
SHAFT UNTIL ROTOR CAN BE SUPPORTED
BY HOIST/SLING.
FIGURE 6-13. REMOVING P7 STATOR ASSEMBLY
23. Verify that the stator is adequately supported and then carefully remove the capscrews from the stator attachment ring.
WARNING To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.
CAUTION Improper stator assembly rig-ging and handling can result in damage to stator and rotor assemblies. Lifting eyes may not be at center-of-gravity position of stator assembly. Therefore, lifting and mov-ing the stator assembly alone, by hoistmov-ing at lifting eyes only, presents the hazard of load imbalance; allowing one end to drop and other end to rise. Make sure the stator is adequately hooked/strapped to maintain level control of stator assembly while lifting and moving.
24. Being careful not to drag the windings on the rotor, move the stator assembly sufficiently away from engine to sling and support the rotor assembly. Do not allow rotor assembly to hang on engine flywheel.
CAUTION Drive disc damage can be
caused by allowing the rotor assembly to hang on flywheel. Use adequate hoist and sling to support the rotor assembly.
25. Reposition or add hoist and sling support for the main rotor, and remove the forklift. See Fig-ure 6-14, Rotor Lift detail.
WARNING To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.
26. Remove the stator assembly, being careful not to drag the windings on the rotor. Place stator assembly away from the chassis in the horizon-tal position.
27. Using the hoist and sling to support the rotor, carefully remove the capscrews and flat wash-ers that secure the drive discs to the engine fly-wheel.
WARNING To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.
28. Remove the rotor assembly and place it on wood blocks in the horizontal position. To avoid possible distortion, do not allow the drive discs and fan to rest on anything.
ROTOR LIFT (EXAMPLE) STATOR LIFT
(EXAMPLE)
RECONNECTION TERMINALS
STATOR
BLOWER
COUPLING
DRIVE DISCS
ROTOR SHAFT
AIR DISCHARGE COVERS
FRAME
ROTATING RECTIFIER ASSEMBLY
PMG STATOR
EXCITER ROTOR ENDBRACKET
PMG ROTOR EXCITER
STATOR
ENDBRACKET/ENGINE ADAPTOR
ROTOR
END BEARING
PRESSURE PLATE
FIGURE 6-14. TYPICAL GENERATOR ASSEMBLY