Generac 3500XL problem

[Charlie Herrmann]

Bought Generac3500XL generator but the engine/gen (model 09441-2) turned over very hard so thought something jammed. Trying now to take generator off engine and have gen casing off but cant figure howto get gen armature off--- I'd think it is just sitting on a splined drive shaft from the B&S engine but wont budge. Any ideas?

[CaseyJoeS.]

usually generators are on a tapered shaft, especially if its a newer design. How old is this setup? Get some PB blaster on it soon! most effective way to get something off a tapered shaft is to give it a "shock" such as tapping it while a puller is on it, along with heating and cooling it.

One trick I have used before is to heat up the spot i want to break loose, and then spray PB blaster on it and as it cools it will pull the PB blaster in because of capilary action. Just dont heat it too much that you might mess up the generator or melt the main engine seal

-Casey

[Motormowers]

Charlie I wouldnt take heat to any part of the generator section of that machine, you could damage the stator or field. They are on the cranks by a taper. The best thing for me has been to spray Kroil in the opening once the end bolt is removed,also spray the crank outside where they meet. Then screw the bolt back in and leave a 1/16" gap between it and the stator. I use a wide blunt bit in an air hammer and shock the bolt head a few times. Be careful to hold the bit tight against the bolt because if it bounces it will flare the bolt head. The works well in removing flywheels and pulleys off shafts too.

[K D Redd]

Remove center bolt. Thread the hole to install a grease zirk. Use grease gun to put pressure in the hole. Sometimes the rotor will pop off immediately. Sometime a little time is needed. You can always add some more pressure if the rotor does not cooperate.

Kent

[Fred M.]

Originally Posted by Charlie Herrmann

Bought Generac3500XL generator but the engine/gen (model 09441-2) turned over very hard so thought something jammed.

Charlie-

From all I've read here, you should be able to unscrew the armature bolt a few turns, give it a whack and dislodge the tapered shaft. However, I haven't tried it on mine.

I have a Craftsman generator that appears to be identical to the Generac 3500XL. I downloaded the owner's manual for the 3500XL from the Generac web site, but it doesn't have as much information about engine construction as the Craftsman owner's manual. The Craftsman parts list uses Generac part numbers.

If you are interested, the Craftsman model number is 580.327251. If you go to the Sears web site, www.sears.com, click on Parts and enter this model number, you should be able to find a parts list and illustrated breakdown. You may want order a copy of the manual.

Sears is a possible source of Generac parts, although limited to stock on hand and you can probably beat their prices.


Fred