Cummins/Onan 6.3 NHEL / 6.5 NH — Electric Starter Assembly

Repair & overhaul

For the Cummins/Onan 6.3 NHEL / 6.5 NH, from the Cummins/Onan service manual.

Applies to: Cummins/Onan NHEL

Procedure

1. Wipe off all dirt and oil from starter components using a clean cloth or filtered low pressure compressed air.
2. Mount brush springs on tabs; turn spring counterclockwise so contact loop is inside brush holder.
3. Push negative brush terminals over through-bolt holes on brush endcap.
4. Insert positive brush stud into hole and torque to 25-30 lb-in. (2.83-3.39 N·m).
5. Bend spring back to allow each brush to be inserted into holder; ensure all brush wires face up.
6. If brushes are at least 0.430 inch (10.9 mm) long, rest brush springs against sides of brushes.
7. Place washer on commutator end of shaft and put armature into brush endcap; push four brushes toward commutator.
8. Place magnetic housing over armature; use a nut driver over end of shaft to hold down armature and endcap.
9. Place spring washer and flat washer on shaft.
10. Place mounting bracket on motor with sleeve bearing and through-bolt lead-ins to inside of motor.
11. Insert through-bolts and torque to 35-45 lb-in. (3.96-5.09 N·m).
12. Wipe dust from helix and gear and apply GE Versilube 322-L; place clutch and helix assembly on motor shaft.
13. Assemble return spring, retainer, and roll pin as required.
14. Mount starter on generator stator housing; tighten mounting screws to 30-33 lb-ft (41-45 N·m).
15. Connect generator set positive (+) battery cable to starter terminal and negative (-) cable to starting battery.

Full service-parts list: Cummins/Onan NHEL →

Source: Cummins/Onan service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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