Cummins/Onan OT-A-4060A / OT-C-10050C — Linear Actuator Removal and Replacement (40 to 125 Amperes)

Repair & overhaul

For the Cummins/Onan OT-A-4060A / OT-C-10050C, from the Cummins/Onan service manual.

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Procedure

1. Disconnect all sources of AC power and disconnect the set starting battery (negative lead first).
2. Open the cabinet door and remove the four machine screws securing the plastic switch cover.
3. Separate the actuator lead wires from the wiring harness and remove wire ties as required.
4. Pry the capacitor(s) loose, remove the end cap, and disconnect the red and white leads from the capacitor and the black lead from the circuit breaker.
5. Remove the socket head capscrews and lock washers securing the actuator to the block assemblies; note the ground wire connection.
6. Disengage the actuator rod from the switch handle and remove the actuator from the block assembly.
7. Remove the capscrew and lock washer securing the rod end assembly, then slide the rod out of the actuator.
8. Insert the rod into the replacement actuator and install the rod end assembly; torque capscrew to 70 to 75 in-lbs (7.9 to 8.5 N•m).
9. Fit the rod assembly into the handle of the closed switch assembly.
10. Secure the actuator with socket head capscrews (4) and lock washers (4); reconnect the ground wire and torque to 25 to 30 in-lbs (2.8 to 3.4 N•m).
11. Connect the black lead to the circuit breaker and the red and white leads to the capacitor terminals.
12. Check switch operation and actuator rod alignment by manually opening and closing both switch assemblies.
13. Install the plastic switch cover and torque to 25 to 30 in-lbs (2.8 to 3.4 N•m).
14. Reconnect the starting battery and AC power, 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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