Cummins/Onan PCC Control 3100 Series — Generator Disassembly
Repair & overhaul
For the Cummins/Onan PCC Control 3100 Series, from the Cummins/Onan service manual.
Applies to: Cummins/Onan DFAA, Cummins/Onan DFAB, Cummins/Onan DFAC, Cummins/Onan DFBF, Cummins/Onan DFCB, Cummins/Onan DFCC, Cummins/Onan DFCE, Cummins/Onan DFE
Before you start
- To prevent personal injury, use adequate lifting devices to support heavy components. Keep hands and feet clear while lifting.
Procedure
- Read through this section first before performing procedures.
- Remove the PMG (Permanent Magnet Generator) per the PMG Removal procedure.
- Remove the air inlet and discharge panels and access covers from control housing and generator.
- Crank or bar the engine/generator to position the rotor so a full pole face is at the bottom of the main stator core.
- Disconnect all load wires from the reconnection terminal block assembly.
- Disconnect the remote control wiring and conduit from the accessory box.
- Disconnect the engine harness connectors (P4, P5, PMG2 through PMG4, F1, F2, P6, P7, P10, J12) and remove harness assembly.
- Support the control housing assembly with a hoist or lifting device.
- Remove control housing fasteners and remove control housing assembly from the generator.
- Remove control housing mounting brackets and assemble lifting eyes to generator.
- Remove air intake components as necessary.
- To remove stator and rotor at the same time, refer to Generator Assembly Removal.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Full service-parts list: Cummins/Onan DFBF →, Cummins/Onan DFCC →, Cummins/Onan DFCE →, Cummins/Onan DFE →
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.