Cummins/Onan DL3 — Generator Disassembly

Repair & overhaul · YD generator

For the Cummins/Onan DL3, from the Cummins/Onan service manual.

Applies to: Cummins/Onan L Series Diesel engine

Procedure

1. Disconnect the negative (-) battery cable to prevent accidental starting.
2. Remove cover from AC control box. Disconnect main stator leads T1-T4 and voltage leads 1 and 2.
3. Remove end bell cover. Disconnect field leads F1 and F2 from terminal board and leads from battery charge regulator.
4. Remove regulator from end bell. Remove load wires and flexible conduit from AC control box. Unplug connectors J1-J3.
5. Remove capscrews securing mounting saddle to stator; control boxes and saddle remove as an assembly.
6. Pull stator leads through opening in bottom of AC control box while lifting assembly free.
7. Remove stud nuts and slide end bell/exciter stator assembly off main stator; pry or jar loose if necessary.
8. Use hoist and safe lifting device to support stator assembly.
9. Remove stator assembly without touching or dragging it on rotor; place on side and block to prevent rolling.
10. Remove two-section air baffle from generator adapter.
11. Support rotor with hoist and sling; remove capscrews attaching drive disk to engine flywheel.
12. Remove rotor assembly and place on wood blocks horizontally; drive disk and fan must not rest on anything.
13. Remove bolts holding drive disk and fan to rotor shaft.
14. Use gear puller to remove end bearing from rotor shaft, pulling on the inner race only.
15. Clamp rotor in fixed position, remove exciter rotor lock nut, remove generator field leads and slide exciter off rotor shaft.

Source: Cummins/Onan service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

More Cummins/Onan repair guides →