Cummins/Onan MDKAD/MDKAE/MDKAF — Generator Reassembly

For the Cummins/Onan MDKAD/MDKAE/MDKAF.

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Procedure

1. Connect the generator field leads to F1+ and F2- terminals on the exciter assembly. Torque to specification.
2. Press the new end bearing onto the rotor shaft.
3. Place the fan and spacer in position next to the rotor hub. Hold them in place using a tie wrap or string. Attach the rotor hub to the drive disk using the original hardware. Torque to 88-95 N·m (65-70 ft-lb).
4. Attach the rotor assembly to the engine flywheel using a hoist and sling to support the rotor. Torque to 38-43 N·m (28-32 ft-lb).
5. Using a hoist and safe lifting device, carefully move the stator assembly into position over the rotor. Bolt the stator to the engine adapter.
6. Install end bell assembly on the stator. Feed the leads from the end bell upwards through the stator opening.
7. Using a lead hammer, tap the end bell at the horizontal and vertical to relieve stress. Install the end bell retainer plugs in the end bell wrapper.
8. Install the end bell bolts and torque them to 0.8-1.0 N·m (7-9 ft-lb).
9. Feed the stator and exciter leads up through the opening in the wrapper through the opening in the control box and saddle. Secure the saddle to the generator.
10. Connect the stator wires to the load wires inside the control box.
11. Connect all applicable control leads (F1, F2, battery charging, etc.) and verify that all connections are secure.
12. Reconnect the AC voltage regulator plug inside the control box.
13. Install the end bell cover.
14. Connect the negative (-) battery cable and test generator operation.

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.