Cummins/Onan — Generator Assembly

For these Cummins/Onan models: 04SXINIA, 102SXIN1A, 208, 2SX5IN, 2SXIN, J-Series, O6SXIN1A, O7SXIN1A.

Applies to: Cummins Onan 04Sxinia, Cummins Onan 102Sxin1A, Cummins Onan 2Sx5In, Cummins Onan 2Sxin, Cummins Onan J Series, Cummins Onan O6Sxin1A, Cummins Onan O7Sxin1A

Procedure

1. Clean and inspect all mating surfaces.
2. Coat the mating area between the generator shaft and the engine crankshaft with a thin film of lubricating oil (Molykote or equal).
3. Install the rotor-through-stud in the engine crankshaft.
4. Install the key in the crankshaft.
5. Slide the rotor over the through-stud and onto the crankshaft. Be careful not to let the weight of the rotor rest on the through-stud.
6. Install the baffle ring.
7. Install generator through studs in the adapter.
8. Install the stator and bearing support (end bell). Tighten the nuts on through-studs.
9. Make certain the B1 lead is placed through the grommet in the baffle ring and out the air discharge opening in the adapter.
10. Now torque down the rotor-through-stud nut (55-60 ft. lb.). Because the stator and bearing support were tightened before tightening the rotor, the rotor and stator are automatically aligned.
11. Tap the bearing support to the horizontal and vertical plane with a lead hammer to relieve stresses on the components (recheck torque).
12. Reconnect the leads to the preheater, centrifugal switch and governor solenoid.
13. Install lead B1 on the adjustable resistor.
14. Check this lead to see that it is short and is kept away from the blower. If necessary when installing a new stator, cut it shorter and reinstall the connector.
15. Install the brushes and brush holders.
16. Close the Magneciter, secure with four capscrews, and install the end cover.

Source: manual:Onan Magneciter Service- SECTION 4. REVOLVING FIELD GENERATORS.pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.