Cummins/Onan 2.5 EGHAA Generator Set

Tools: feeler gauge, wrenches

1. Adjust only when engine is at ambient temperature.
2. Rotate engine until piston is at top dead center and both valves closed.
3. Check clearance between valve stem top and rocker arm with feeler gauge.
4. Loosen locking nut and turn adjusting nut to obtain correct clearance.
5. Tighten locking nut and recheck clearance.
6. Check rocker arm bolts have not loosened.

⚠ Disconnect battery before servicing to prevent accidental starting.

Tools: jumper leads

1. Connect jumper lead between battery positive (+) terminal and solenoid S terminal.
2. Momentarily connect jumper between battery negative (-) and solenoid body.
3. Solenoid contacts should close; replace solenoid if it does not activate.

⚠ Fuel presents fire or explosion hazard; keep ABC extinguisher nearby.

1. Close fuel supply valve; run set until it runs out of fuel; let cool.
2. Remove fuel line from shutoff valve and collect fuel in a container.
3. Unscrew sediment bowl from fuel supply valve and clean it.
4. Remove screen and clean dirt and particulate off the screen.
5. Reinstall screen and sediment bowl; attach fuel line securely.

⚠ Exhaust gas hazard; do not operate with any exhaust leaks.

Tools: wrenches

1. Allow set to cool before servicing.
2. Remove heat shield covering exhaust pipe and engine.
3. Remove mounting nuts securing muffler flange to engine.
4. Remove screws securing muffler to support bracket and generator flange; remove exhaust gasket.
5. Install new exhaust gasket and muffler; tighten hardware to specified torque.

⚠ Close fuel valve and drain float chamber; no flame or spark near fuel system.

Tools: wrenches

1. Remove air cleaner assembly.
2. Disconnect governor linkage, fuel line, throttle linkage, and choke control linkage.
3. Remove carburetor assembly from the intake elbow.

⚠ Moving parts can cause severe personal injury; use protective equipment.

1. Engage outer end of spiral spring in starter notch and rewind into reel.
2. Apply heat resistant grease to the spring.
3. Install reel, friction spring, ratchet guide, ratchet, friction plate and mounting nut.
4. Wind reel the counted number of revolutions and hold to prevent unwinding.
5. Thread starter rope through reel and case and secure to handle.
6. Check ratchet operation before installing.

⚠ Spiral spring is under tension; wear protective eye wear, gloves, clothing.

1. Remove recoil starter assembly from spiral case and check operation.
2. Slowly pull starter rope all the way out and note revolutions.
3. Hold reel with pressure, remove rope, allow reel to unwind slowly.
4. Remove friction plate mounting nut, friction plate, ratchet guide, ratchet, friction spring.
5. Slowly lift reel while rotating to disengage spiral spring; note coil direction.
6. Carefully remove the spring.

Tools: gear puller, press

1. Remove rotor assembly.
2. Cover rotor shaft end with hardened washer; use gear puller to remove bearing.
3. Place rotor shaft engine end down on protective surface.
4. Press new bearing onto shaft, pressing inner race only, to original position.

Tools: strap wrench, torque wrench

1. Clean tapered mounting shaft and rotor shaft of dirt and oil.
2. Install rotor onto tapered shaft; insert through-bolt and hand tighten.
3. Secure rotor with a strap wrench.
4. Tighten through-bolt to specified torque.

Tools: lead hammer

1. Loosen rotor through-bolt two or three turns.
2. Tap through-bolt head with lead hammer to loosen rotor from tapered shaft.
3. Remove rotor through-bolt and carefully remove rotor.
4. Place rotor on a soft surface to prevent winding damage.

Tools: torque wrench, screwdriver

1. Assemble end bell to stator if previously separated.
2. Install stator assembly over rotor without damaging windings.
3. Secure stator to adapter with four bolts at specified torque.
4. Secure end bell to frame at specified torque.
5. Pull recoil starter slowly to check rotor-stator alignment.
6. Reconnect all wiring; tighten terminal block nuts.
7. Install brush block and secure with mounting screw.
8. Place end cover over end bell and secure.

⚠ On AVR models the brush block assembly will be damaged if not removed.

Tools: screwdriver, wrenches

1. Remove generator cover and disconnect all wiring connectors; tag wires.
2. On AVR models remove brush block mounting screw and lift brush block off.
3. Remove mounting bolts securing end bell to frame.
4. Remove stator mounting bolts and pull end bell and stator off together.
5. For stator replacement remove two screws securing stator to end bell; separate carefully.