Cummins/Onan — Starter Assembly
Repair & overhaul · Electric starter
From a Cummins/Onan service manual covering: P216, P218, P220, P248. Check it applies to your exact model before use.
Applies to: Cummins/Onan P216, Cummins/Onan P218, Cummins/Onan P220, Cummins/Onan P248
Procedure
- Install the seal in the nose housing and install the overrunning clutch on the armature shaft.
- Slide the stopper on the armature shaft and position the snap ring in the groove.
- Pull the stopper all the way over the snap ring; tap the snap ring into the groove with a punch while maintaining tension on the stopper.
- Apply grease (recommended grade Multemp PS No. 2) to the armature shaft spline, both bushings, stopper, pinion gear, and sliding portion of lever.
- Fit the overrunning clutch into the lever and install it with the armature in the front bracket.
- Install the lever retainer and spacer and position the frame assembly over the armature on the front bracket.
- Install the brush holder assembly and position the brushes; make certain the positive lead wires are not grounded.
- Install washers on the rear end of the armature shaft to obtain a thrust gap of 0.002 to 0.020 inch (0.05 to 0.5 mm).
- Install the rear bracket and secure the brush holder to the rear bracket with two machine screws.
- Install and tighten the two through bolts and install the solenoid plunger in the lever.
- Secure the solenoid to the front bracket with two machine screws.
- After assembly, adjust the pinion clearance to 0.02 to 0.08 inch (0.5 to 2.0 mm) using shims if necessary.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Solenoid Screws 54 lb-in (6.1 Nm)
- Brush Retaining Screws 33 lb-in (3.7 Nm)
- Through Bolts 51 lb-in (5.8 Nm)
- Armature shaft thrust gap 0.002 to 0.020 inch (0.05 to 0.5 mm)
- Pinion clearance 0.02 to 0.08 inch (0.5 to 2.0 mm)
Full service-parts list: Cummins/Onan P216 →, Cummins/Onan P218 →, Cummins/Onan P220 →, Cummins/Onan P248 →
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.