Cummins/Onan — Linear Actuator Removal and Replacement (40 to 125 Amperes)

Repair & overhaul

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

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Procedure

1. Disconnect all AC power sources and the starting battery (negative [-] lead first).
2. Open cabinet door; remove the four machine screws and lift off the plastic switch 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 actuator leads and the black lead from the circuit breaker.
5. Remove the socket head capscrews and lock washers securing the actuator to the block assemblies.
6. Disengage the actuator rod from the switch handle and remove the actuator.
7. Remove the rod end assembly and slide the rod out of the actuator.
8. Insert the rod into the replacement actuator; install the rod end assembly and tighten capscrew to 70 to 75 in-lbs.
9. Position the actuator motor on the block assemblies and fit the rod into the handle of the closed switch assembly.
10. Secure the actuator with socket head capscrews and lock washers; reconnect the ground wire to the lower left screw.
11. Connect the black lead to the circuit breaker and the red and white leads to the capacitor terminals (red to C1 Terminal 1).
12. Replace the capacitor end cap(s) and install the capacitor(s) in the bracket(s).
13. Check operation and alignment by manually opening and closing both switch assemblies.
14. Install the switch cover and tighten to 25 to 30 in-lbs.
15. Reconnect battery and power sources; test the switch 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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