Cummins/Onan EH09-2D Engine

Tools: Feeler gauge

1. Adjust the air gap between flywheel and pulsar coil to 0.5 mm with a feeler gauge.
2. Attach the pulsar coil to the engine and tighten the bolt in place.

Tools: AC voltmeter, AC ammeter, Frequency meter

1. Use a circuit with a load such as a hot plate or lamp with a power factor of 1.0.
2. Adjust the load and rpm.
3. Check that the voltage range is as specified at the rated amperage and rated rpm.

⚠ If insulation resistance is less than 1 MΩ, disassemble the generator and measure stator, rotor and control panel individually.

⚠ Insulation failure may cause electrical leak which may result in electrocution.

Tools: Megger tester (500 V range)

1. Short-circuit the terminals of an AC receptacle using a wire to discharge remaining electricity.
2. Connect the megger tester across either one output terminal of the AC receptacle and the ground terminal.
3. Measure with the AC breaker on.
4. An insulation resistance of 1 MΩ or more is normal (factory value is 10 MΩ or more).

⚠ Wear protective goggles before starting assembly.

⚠ Be sure the retaining ring is fitted into the grooves.

Tools: Protective goggles

1. Install the ratchet and fasten it with retaining ring E.
2. Install the spiral spring in the reel.
3. Apply grease to the case.
4. Properly orient the inner end of the spring.
5. Hold the reel and softly drop it into the case from the top.
6. Move the reel gently counter-clockwise, making sure the spring catches.
7. Install the ratchet guide and return spring into the reel.
8. Install the friction spring, friction plate and retaining ring C.
9. Thread the rope through the reel and tie the end.
10. Wind the rope clockwise seven times with the rope hanging from the reel.

⚠ Wear protective goggles before starting disassembly.

⚠ The pull of the spring is maximized while the rope is fully pulled out; do not release it suddenly.

⚠ Place the reel on a flat table without dropping or shaking.

Tools: Long-nose pliers, Retaining-ring pliers, Protective goggles

1. Hold the starter handle and pull the starter rope out.
2. Pull out all of the rope, and align the rope guide and the knot of the rope inside the reel.
3. Hold the reel with both thumbs so fingers do not become entangled.
4. Pull the knot of the rope out from the reel and loosen it.
5. Slowly rewind the rope until the reel stops while controlling the reel with both thumbs.
6. Hold the case and remove retaining-ring C with the ring pliers.
7. Beginning at the top, remove the retaining-ring, friction plate and ratchet.
8. Move the reel left and right at 1/4 turns until it moves smoothly.
9. Slowly lift the reel, removing it from the case.

⚠ Memorize the location of each part when disassembling; tag parts for reassembly.

⚠ Remove battery before disassembly.

⚠ Do not clean electrical parts with oil or water.

Tools: Screw driver, Pliers, 10mm Box wrench, 12mm Box wrench, Flywheel puller

1. Remove the side panels (Left, Right).
2. Remove the rear cover (four screws).
3. Remove the rolling wire and choke wire.
4. Remove the recoil starter handle and guide.
5. Remove the control panel.
6. Remove the case body (Left, Right).
7. Remove the rear frame.
8. Remove the fuel cock bracket.
9. Remove the fuel tank and fuel cock.
10. Remove the control panel and disconnect the three couplers.
11. Remove the inverter unit (two couplers).
12. Remove the fuel pipes (carburetor side and crank case side).
13. Remove the air cleaner and carburetor.
14. Remove the front frame.
15. Remove the base inverter, stator/rear cover, rotor, blower housing, flywheel, recoil starter, muffler, ignition coil and cylinder baffle.

⚠ Wipe off any oil from the tapered shaft and hole before assembling the flywheel.

⚠ Do not forget to put the 2 pieces of pipe knock.

⚠ Avoid damaging the magnet of the rotor.

Tools: Screw driver, 10mm Box wrench, 12mm Box wrench, Feeler gauge

1. Install the cylinder baffle.
2. Install the ignition coil into the ignition coil bracket.
3. Install the muffler.
4. Install the recoil starter to the crankcase.
5. Install the flywheel.
6. Adjust the air gap between flywheel and pulsar coil to 0.5 mm with a feeler gauge.
7. Install the pulsar coil and grommet.
8. Install the blower housing.
9. Install the rotor.
10. Install the rear cover and stator into the rotor.
11. Install the base inverter into the engine main body.
12. Install the front frame (L) and (R) onto the base inverter.
13. Install the air cleaner base plate and carburetor.
14. Install the air cleaner element and cover.
15. Install the fuel pipes, inverter unit and couplers, fuel tank and fuel cock, rear frame, case body and control panel, recoil starter guide, choke/rolling wires, rear cover and side panels.