Cummins/Onan P2400 / P3500 — Generator Disassembly
Repair & overhaul
For the Cummins/Onan P2400 / P3500, from the Cummins/Onan service manual.
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Before you start
- Place a wooden block and a shop rag under the rotor for support.
- Wear safety glasses or goggles when striking the end of the rotor puller.
Procedure
- Place a brace block underneath the alternator.
- Remove the two bolts on the end cap to remove the end cap.
- Disconnect the DC coupler and field winding coupler.
- Unscrew the nuts holding the main winding leads and disconnect them.
- Remove the bolt holding the field windings and disconnect the connector.
- Remove the brush block assembly.
- Remove the voltage regulator.
- Remove the muffler mounting bracket.
- Remove the ground wire from the top of the alternator assembly.
- Remove the alternator cooling fan shroud.
- Remove the rotor through bolt.
- Remove the nuts securing the alternator to the vibration isolators.
- Remove the four bolts connecting the alternator to the engine adaptor.
- Carefully remove the stator assembly from the generator adaptor.
- Use a rotor puller to remove the rotor; torque the puller to 6.9 Kg-cm (50 ft-lbs).
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Torque the puller to 6.9 Kg-cm (50 ft-lbs).
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.