Cummins/Onan RGA-IN1 — Generator Disassembly
Repair & overhaul
For the Cummins/Onan RGA-IN1, from the Cummins/Onan service manual.
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Before you start
- Generator components are heavy and can cause severe personal injury if dropped during service.
Procedure
- Disconnect negative (-) battery cable.
- Remove control box cover and disconnect all stator leads. Mark leads.
- Remove end bell cover and remove field leads F1 and F2.
- Remove load wires and flexible conduit from control box.
- Unplug wiring harness from voltage regulator to generator. Remove regulator.
- Remove capscrews securing control box mounting saddle to stator.
- Pull stator leads through opening. Do not disconnect engine DC control wires.
- Set control box and saddle on top of engine.
- Remove end bell stud nuts and slide off end bell and exciter stator.
- Support stator assembly with hoist. Place support under engine.
- Remove stator assembly, place on side horizontally.
- Support rotor with hoist, remove capscrews attaching drive disc to engine flywheel. Remove rotor assembly, place on wood block horizontally.
- Remove bolts holding drive disc and fan to rotor shaft; remove bolts holding drive disc to fan. Use gear puller to remove end bearing.
- Clamp rotor, remove exciter rotor lock nut.
- Remove generator field leads from exciter rotor and slide exciter off rotor shaft.
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.