Cummins/Onan DL3 — Generator Reassembly

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. Slide exciter rotor over generator shaft and woodruff key; install exciter nut and apply torque values shown in Figure 2-9.
2. Connect generator field leads to F1+ and F2- terminals on exciter assembly; torque to values shown.
3. Press end bearing onto rotor shaft.
4. Assemble rotor fan and drive disk to engine flywheel using hoist and sling; chamfer must be on flywheel side.
5. Apply torque values shown in Figure 2-9. Install air baffle.
6. Using hoist and safe lifting device, carefully move stator into position over rotor with leads exiting in top position.
7. Install end bell stud bolts through stator and into generator adapter.
8. Apply thin film of Molykote grease to mating surfaces of end bearing and end bearing hole.
9. Install end bell assembly on stator with generator lead opening at top position.
10. Replace stud nuts and torque to 20 ft lbs (27 Nm); install battery charge regulator bracket in upright position with ground lead terminal under mounting screw.
11. Using a lead hammer, tap end bell at horizontal and vertical plane to relieve stress; retorque end bell stud nuts.
12. Route generator leads through opening in AC control box and secure saddle to generator.
13. Connect control leads and verify all connections are correct and secure.
14. Connect field leads F1 and F2 to terminal board and leads to battery charge regulator; install end bell cover.
15. Connect load wires to correct terminals, connect negative (-) battery cable and test generator operation.

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.

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