Cummins/Onan MDKAD/MDKAE/MDKAF — Generator Disassembly

For the Cummins/Onan MDKAD/MDKAE/MDKAF.

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Procedure

1. Disconnect the negative (-) battery cable from the battery to prevent accidental starting of the generator set while servicing.
2. Remove the generator set from the boat and place it on a sturdy work bench.
3. Remove the cover from the control box. Disconnect all stator leads, control box ground leads to the voltage regulator connector plug, voltage regulator connector plug, and load circuit breaker leads.
4. Remove the end bell cover.
5. Remove the screws securing the control box mounting brackets. The control box and brackets are removed as an assembly.
6. Lift the control box and bracket free of the stator.
7. Brace the stator in position, then remove the end bell bolts and slide off the end bell and exciter stator.
8. Remove the bolts going through the generator vibration isolators. Lift the set using the genset lifting bracket.
9. Place a lifting strap around the stator and lift until it just begins to tighten. Loosen the bolts around the edge of the stator wrapper, then remove the stator assembly.
10. Using a hoist and sling to support the rotor, carefully remove the bolts that attach the drive disc to the engine flywheel.
11. Remove the rotor assembly and place it on a wood block in the horizontal position.
12. Remove the bolts that hold the drive disc to the rotor shaft.
13. Use a gear puller to remove the end bearing from the rotor shaft.
14. Clamp the rotor in a fixed position.
15. Remove the generator field leads from the exciter rotor and use the end bearing puller to pull the exciter rotor off the rotor shaft.

Source: manual:981-0520B Onan MDKAD MDKAE MDKAF Service Manual (2-2013).pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.