Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
This section contains instructions for removal and
installation of major components of the generator
set to facilitate repair and overhaul procedures.
Removal of assemblies and repair and overhaul in-
structions are covered in subsequent sections of
2-11. Generator Removal.
See figure 2-1 for location of major components.
a. Disconnect the ground cable from the battery.
b. To remove the following refer to the Operator
and Organizational Maintenance Manual.
(1) Receptacle panels (as required).
(2) Manual speed control.
(3) Fault indicator.
(4) Control cubicle.
(5) Rear grille.
(6) Rear panels and doors.
(7) Rear roof and corner posts.
(8) Main load contactor.
(9) Load terminal board.
(10) Reconnection board.
(11) Air cleaner.
c. See figure 6-2 for removal of main generator
leads from current transformer assembly. Before
removing current transformer assembly, tag 18
harness wires from terminal strip and identify the
leads which are passed through the current trans-
formers more than once.
d. See para 6-8 for removal of current trans-
e. On Class I sets only, remove the governor
control unit and mounting bracket. (See para 7-3. )
f. Remove the relay table group. (See para 8-5.)
g. Remove generator.
See figure 2-2 and proceed
(1) Position engine jacking supports on the
engine flywheel housing. Adjust engine jacking
studs by hand until firm contact is established with
(2) Insert generator lifting eye bolt in top of
generator housing and attach suitable lifting device.
(3) Remove two screws and two flat washers
and two lockwashers on each side of generator
housing near forward end and remove access cover
(4) Remove 4 generator mounting screws, 8
washers and 4 nuts.
(5) Adjust jacking studs to support the weight
of the engine, approximately 1/2 turn beyond hand
(6) Reaching through inspection holes in gen-
erator housing, bend lockstrips away from heads of
eight fan-coupling screws securing generator coup-
ling. Remove the screws to separate the engine and
generator at the coupling. Removal of these screws
also frees the fan. To facilitate access to the
screws, rotate the engine.
(7) Reaching through inspection holes in for-
ward end of generator, remove 12 rim coupling
screws and washers around perimeter of flange
mating engine to flywheel housing.
2-12. Generator Installation.
Using a suitable lifting device, position main
generator mounting pads in skid base and line up
generator mounting flange with flywheel housing.
b. Install 12 screws and washers through gener-
ator front flange into flywheel housing. Torque
screws to 35 foot-pounds.
c. Reach through generator inspection holes,
support fan to line up holes and install eight fan
coupling screws each with a lockstrip. Before
tightening make sure lockstrip extension is in small
hole adjacent to threaded screw hole. Torque bolts
to 110 foot-pounds.
Bend lockstrip corners against
screw head flats.
d. Install four main generator mounting screws
and washers and secure with four nuts and 8 washers.
Do not torque screws at this time.
e. Loosen and remove engine support brackets.
f. Torque generator mounting screws to 440
g. Install screen and access cover on generator
and secure with two screws, two flat washers, and
two lockwashers on each side.
h. See figure 8-1 and install relay table group in
reverse order of removal.