Cummins/Onan P2400 / P3500 — Generator Reassembly

Repair & overhaul

For the Cummins/Onan P2400 / P3500, from the Cummins/Onan service manual.

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Procedure

1. Wipe dirt and oil off the tapered portion of the rotor and crankshaft.
2. Install the stator assembly on the generator adapter.
3. Make sure the crankcase grommet is inserted securely.
4. Use four stator bolts to install the alternator on the engine adapter; do not tighten yet.
5. Use the nuts to install the alternator on the vibration isolators.
6. Tighten the stator bolts in a crisscross pattern to 8-12 N·m.
7. Install the washer and rotor through bolt; torque to 43-47 N·m.
8. Install the alternator cooling fan shroud.
9. Install the ground wire on the top of the alternator assembly.
10. Install the muffler mounting bracket.
11. Install the voltage regulator.
12. Install the brush block assembly.
13. Use a bolt to install the field windings and connect the connector.
14. Connect the main winding leads and secure with nuts.
15. Connect the DC coupler and the field winding coupler; install the end cap.

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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