7. DISASSEMBLY AND ASSEMBLY
7-1 PREPARATION and PRECAUTIONS
1) Be sure to memorize the location of individual parts when disassembling the generator so that the generator can be reassembled correctly . Tag the disassembled part with the necessary information to facilitate easier and smoother reassemble .
2) For more convenience, divide the parts into several groups and store them in boxes .
3) To prevent bolts and nuts from being misplaced or installed incorrectly, replace them temporarily to their original position .
4) Handle disassembled parts with care; clean them before reassemble using a neutral cleaning fluid .
5) Use all disassembly / assembly tools properly, and use the proper tool for each specific job .
7-2 DISASSEMBLY PROCEDURES
7-2-1 FUEL TANK
(1) Shut the fuel strainer and discharge fuel from caburetor .
(2) Disconnect rubber pipe from the strainer .
(3) Remove the fuel tank .
M6 flange bolt . . . 4 pcs .
Rubber(tank) . . . 4 pcs .
7-2-2 CONTROL PANEL and CONTROL BOX
(1) Remove the control panel .
M6 flange bolt . . . 4 pcs .
M4 flange bolt . . . 4 pcs .
(2) Disconnect the connectors on the wiring from the control panel to the alternator .
(3) Remove the control box .
FUEL TANK
CONTROL BOX
CONTROL PANEL
CONTROL PANEL
M4
M6
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7-2-3 ALTERNATOR
(1) Remove the end cover .
M6 flange bolt . . . 2 pcs .
(2) Disconnect the connectors on the wiring from the alternator .
(3) Remove the AVR unit, brush holder and diode stack .
END COVER
FLANGE
BOLT
Disconnect the connectors
EARTH (GROUND) WIRE
BRUSH
HOLDER
DIODE
STACK
(4) Set the generator set with the rear cover upwards .
NOTE) Before starting this work, make sure engine oil has been discharged.
(5) Remove the two flange nuts fixing rear cover onto the mount rubbers .
M8 flange nut . . . 2 pcs .
(6) Remove the rear cover .
RGX3000 M6 × 140mm . . . 3 pcs .
RGX3800 M6 × 165mm . . . 3 pcs .
RGX5100 M6 × 165mm . . . 4 pcs .
(7) Take out stator cover with claws (2 pcs) raised up by using screw driver .
(8) Remove the stator .
NOTE : The stator is heavy. Be careful do not hit the coil of the stator to the rotor.
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EARTH (GROUND) WIRE
AVR UNIT
REAR
COVER
MOUNT
RUBBER
FLANGE NUT
STATOR COVER
(9) Take off the through bolt of the rotor .
(10) Use a bolt and oil as a tool for pulling out rotor in the following procedures :
1 . Pour engine oil into the center hole of rotor shaft . Fill with oil to the shaft end .
2 . Prepare a bolt with the following thread size : M10 × 1 .5 (RGX3000 / RGX3800)
M12 × 1 .75 (RGX5100)
3 . Apply a few turns of seal tape around the tip of the bolt .
SEAL TAPE
SEAL TAPE
4 . Screw the bolt into the thread of the rotor shaft .
5 . Torque the bolt using a socket wrench until the rotor comes off loose .
* The hydraulic pressure inside the rotor shaft takes apart the rotor from the engine shaft .
(11) Remove the front cover .
M8 × 20 bolt(countersunk head) . . . 4 pcs .
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FRONT COVER
