Cummins/Onan — DC Control Wiring Installation
Installation · control box TB1
From a Cummins/Onan service manual covering: C400 D5e, C400D5, C450 D5e, C450 D6e, C450D5, C450D6, C500 D5e, C500 D6e, C550, C550 D5, QSX15. Check it applies to your exact model before use.
Applies to: Cummins/Onan C400 D5e, Cummins/Onan C450 D5e, Cummins/Onan C450 D6e, Cummins/Onan C450D5, Cummins/Onan C450D6, Cummins/Onan C500 D5e, Cummins/Onan C500 D6e, Cummins/Onan C550 D5, Cummins/Onan QSx15, Cummins/Onan QSX15-G8/G9 engine
Before you start
- Hazardous voltage! Ensure all power is off before performing control wire installation.
- Always run control circuit wiring in separate metal conduit from AC power cables.
Procedure
- Route the control wiring through the bottom of the control housing, keeping DC wiring away from high voltage AC wiring.
- Use cable ties to keep control wiring away from sharp edges and AC power cables within the control housing.
- Use 20 gauge stranded copper wire for digital connections less than 305 metres (1000 feet).
- Use 18 gauge stranded copper wire for digital connections 305 to 610 metres (1000 to 2000 feet).
- Determine the gauge of stranded copper wire for relay connections according to the devices attached.
Tools required
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- 20 gauge stranded copper wire < 305 m (1000 ft)
- 18 gauge stranded copper wire 305 to 610 m (1000 to 2000 ft)
Full service-parts list: Cummins/Onan C400 D5e →, Cummins/Onan C450 D5e →, Cummins/Onan C450 D6e →, Cummins/Onan C450D5 →, Cummins/Onan C450D6 →, Cummins/Onan C500 D5e →, Cummins/Onan C500 D6e →, Cummins/Onan C550 D5 →, Cummins/Onan QSx15 →
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.