Cummins/Onan — Linear Actuator Removal and Replacement (150 to 260 Amperes)

Repair & overhaul

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

Applies to: Cummins/Onan OTPC

Procedure

1. Disconnect both Source 1 and Source 2 and the genset starting battery (negative lead first).
2. Remove the two self-locking nuts and two machine screws securing the plastic switch cover and lift off the cover.
3. Separate the actuator lead wires from the wiring harness; remove wire ties as required.
4. Pry the capacitor(s) loose; disconnect the red and white leads from the capacitor terminals.
5. Disconnect the black actuator wire from the circuit breaker and the ground wire from the end of the actuator.
6. Remove the hardware securing the actuator to the switch assemblies and lift out the spacers (4) and barriers (2).
7. Disengage the actuator rod from the switch handle and remove the actuator.
8. Remove the rod end assembly from the actuator rod and slide the rod out of the actuator motor.
9. Insert the actuator rod into the replacement motor; install the rod end assembly and tighten capscrew to 70-75 in-lbs (7.9-8.5 Nm).
10. Position the actuator over the switch assemblies with lead wires at the bottom; fit the rod assembly into the handle of the closed switch assembly.
11. Secure the actuator with hex head capscrews (4), lock washers (4), flat washers (4), barriers (2), and spacers (4); tighten to 25-27 in-lbs (2.8-3.0 Nm).
12. Connect the black lead to the circuit breaker and the red and white leads to the capacitor terminals.
13. Connect the ground wire; check operation and rod alignment; secure the plastic cover and tighten to 25-30 in-lbs.
14. Reconnect the starting battery and power sources; test and close the cabinet.

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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