Cummins/Onan — Linear Actuator Removal and Replacement (800 and 1000 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 capscrew, flat washer, and lock washer securing a rod end assembly to the actuator rod; remove the rod end assembly and slide the rod out.
3. Remove the twelve machine screws securing the three plastic switch covers and lift off the covers.
4. Separate the actuator lead wires from the wiring harness; remove wire ties as required.
5. Pry the capacitors loose; disconnect the red and white leads from the capacitor terminals.
6. Disconnect the black actuator lead from the circuit breaker and the ground wire from the end of the actuator.
7. Remove the hardware securing the actuator to the switch assemblies and lift out the spacers and actuator motor.
8. Hold the actuator motor and spacers (4) in position over the switch assemblies with lead wires at the bottom.
9. Secure the actuator motor with hex head capscrews (4), lock washers (4), and flat washers (4); tighten to 70-75 in-lbs (7.9-8.5 Nm).
10. Connect the black lead to the circuit breaker and the red and white leads to the capacitor terminals.
11. Replace the capacitor end caps and install the capacitors; connect the ground wire and secure leads with wire ties.
12. Place the plastic switch covers in position and tighten to 25-30 in-lbs (2.8-3.4 Nm).
13. Insert the actuator rod into the motor, secure the rod end assembly to 70-75 in-lbs, and fit into the handle of the closed switch assembly.
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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