Major Disassembly - Guardian 5240 Diagnostic Repair Manual

SECTION 6.1

MAJOR DISASSEMBLY

MAJOR DISASSEMBLY
STATOR/ROTOR/ENGINE REMOVAL:
For stator removal, follow Steps 1-14. For rotor remov-
al, follow Steps 1-15. For Engine removal follow Steps
1-16.
1. Remove door.
2. Set the AUTO-OFF-MANUAL switch to OFF. Disconnect
battery cables. Remove Fuse F1. Remove the utility
power source to the generator. Turn off fuel supply to
the generator.
3. Remove Control Panel Cover: Using a 10 mm sock-
et, remove the control panel cover. Remove two nuts
located on back panel using a 7mm socket. Remove two
control panel screws.
4. Disconnect Stator Leads/Connectors: Remove the
stator leads (Wire 11 and Wire 44) from the main circuit
breaker (on 10/13/16 kW units remove Wires 11 and
44 from the Idle Control Transformer also). Remove
the stator leads (Wire 22 and Wire 33) from the neutral
lug. Unplug C1, C2 and C3 connectors from the control
panel. For control panel removal only, remove Wires
N1/N2 and Wires 23/194 from the terminal strip, and the
ground and neutral wires from the control panel.
5. Disconnect Fuel Hoses: Remove the two fuel hoses at
the air box assembly. Some models are equipped with
an additional third fuel hose. Remove it also if equipped.
Pull hoses back into the battery compartment. For con-
trol panel removal only remove Wire Nos. 0 and 14 from
the fuel solenoid.
6. Remove Front and Back Exhaust Enclosure Covers:
Using a 10mm socket, remove the six bolts and four
nuts from the exhaust covers. Remove the covers.
Remove the nut and bolt attaching to the roof left side
folding support and bottom support bracket.
Figure 1. Exhaust Side Enclosure Removed
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PART 6
7. Remove Muffler: Using a 10mm socket remove the
eight bolts from the flex cover. Loosen the muffler pipe
clamp closest to the engine exhaust manifold. Loosen
the exhaust clamp and remove the tailpipe. Remove four
bolts from the bracket for muffler access located in the
center of the alternator divider panel. Using a 13mm
socket remove two muffler nuts and remove two bolts
that mount the muffler. Pull back on the muffler flex pipe
and remove the muffler assembly. Using a 10mm socket
remove four bolts from the flex base and remove flex
base.
8. Remove Exhaust Side Enclosure: Using a 13mm
socket remove the three bottom base enclosure bolts.
Using a 10mm socket remove three side enclosure
mounting bolts. Remove enclosure.
9. Remove fan housing cover: Using a 10mm socket
remove four 10mm bolts from the cover. Remove the fan
housing cover.
10.Remove Rotor Bolt: Using a 9/16" socket, remove one
rotor bolt.
11.Remove Fan: Attach a steering wheel puller to the fan
using two M8 x 1.25 bolts. Remove the fan from the
rotor.
12.Remove Alternator Divider Panel: Using a 10mm
socket remove two side panel nuts. Using a 13mm sock-
et remove two bottom base bolts. Remove the panel.
Figure 2. Using a Steering Wheel Puller to
Remove Fan From Rotor
13.Stator Removal: Using a 13mm socket, remove the
two nuts from the alternator mounting bracket/rubber
mounts. Lift the back end of the alternator up and place
a 2"x 4" piece of wood under the engine adapter.
DISASSEMBLY