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Home›Repair guides›Cummins/Onan›Removing Transfer Switch Motor Mechanism (800 Ampere and Larger, ITE)

Cummins/Onan — Removing Transfer Switch Motor Mechanism (800 Ampere and Larger, ITE)

Repair & overhaul

From a Cummins/Onan service manual — check it applies to your exact model before use.

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Before you start

  • Never perform maintenance or service of the transfer switch unless all power is removed and the generator set is disabled; otherwise a serious shock hazard exists

Procedure

  1. Open the cabinet doors; move the operation selector switch on the engine control to STOP; disconnect the ground cable of the starting batteries.
  2. Remove AC line power from the automatic transfer switch.
  3. Move the motor disconnect switch S8 to OFF.
  4. Remove the manual operator handle from its stored position.
  5. Push handle on drive shaft and turn handle clockwise to open the transfer switch contacts (indicator should read OFF).
  6. Loosen the two top Phillips screws which hold the cover with the ITE nameplate; slide cover up and off to expose terminal block.
  7. Remove the top wires only from the terminal block (note positions) and push the wires out through the grommet.
  8. Remove the three motor leads from the terminal block.
  9. Remove the three Phillips screws while holding the motor and drive assembly; pull assembly straight back and out.
  10. Remove the bottom two Phillips screws and slide the bottom cover off the transfer switch.
  11. Remove remaining wire leads to terminal block from motor cutoff switch (note positions).
  12. Remove the Phillips screws previously loosened; pull the small panel, gear and drive shaft assembly straight out.
  13. Remove the two nuts with an 11/16-inch wrench and remove the motor assembly or sheet metal panel over the transfer switch.
  14. Remove the four screws from the plastic transfer switch cover and pull off cover.
  15. Reassemble in the reverse order; be sure motor disconnect switch is in original position when installing gear and shaft assembly.

Tools required

Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.

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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