Cummins/Onan RSS100 / RSS200 — Switch Assembly Removal and Replacement Procedure
Repair & overhaul · Transfer switch mechanism
For the Cummins/Onan RSS100 / RSS200, from the Cummins/Onan service manual.
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Before you start
- The transfer switch presents a shock hazard that can cause severe personal injury or death. Before beginning installation, remove all sources of AC power.
- Always disconnect a battery charger from its AC source before disconnecting the battery cables.
- Disconnect the starting battery cables before performing service; remove the negative (-) cable(s) first.
Procedure
- Move the operation selector switch on the generator to Stop (Off).
- If there is an external battery charger, disconnect it from its AC power source.
- Disconnect the generator starting battery (negative [-] lead first).
- Remove all AC power to the automatic transfer switch.
- Remove the cabinet door panel(s).
- Remove all control and power wiring from the switch terminals.
- Loosen the six 1/4-20 bolts securing the mechanical lugs.
- Loosen and remove two screws, nuts, and washers securing the bracket at the load and emergency side.
- Loosen and remove all M6 nuts and lock washers securing the switch to the rear wall.
- Remove the switch and bottom bracket from the cabinet.
- Mark the bus bar of each phase and remove all bus bars from the old switch.
- Install the bus bars on the new switch per the markings, long end toward the breaker.
- Install the new switch using hardware from step 9; torque the M6 nuts to 50 in-lbs (5.6 N·m).
- Install the bracket at the load and emergency side; torque the 1/4-20 bolts to 80 in-lbs (9 N·m).
- Reinstall the cabinet door panel(s) and restore power.
Specs & values
- M6 nuts: 50 in-lbs (5.6 N·m)
- 1/4-20 bolts: 80 in-lbs (9 N·m)
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.