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Onan Generator Troubleshooting - contributed by Mickey Mathias.
The following information was provided by Alan Robinson a Cert.
Onan Tech.
(The following is a compilation of several e-mails between myself and Alan
regarding my genset problem. Some of the information below will only make sense
and or apply to my specific case so don't let that confuse you if you try and
use this information to assess your problem.)
The problem was engine would start but quit as soon as the start
button was released. (Onan Emerald 4kw)
(WEBMASTER COMMENT: this information is specific to the model listed - your particular model may have different specifications and wiring connections. Therefor this article is intended for general information only. Before doing anything, verify your model number and specifications)
* It sounds like one of two things - either you are not getting
the voltage from the control board to the voltage regulator while cranking
(the field flash voltage that establishes some initial output from the
genset), or the control board is providing the voltage but there is an open
circuit in the voltage regulator, and the field flash voltage isn't being passed
along to the brushes.
* To tell which is which, locate the voltage regulator module
inside the control box (bolted down at bottom left - has a capacitor molded
into the top, and a short multi-wire pigtail to a twelve-conductor socket mated
to a matching twelve-conductor plug in the wiring harness - J4/P4). Set your
voltmeter to dc volts, ground the negative lead, and back-probe pin 7 - you
should see approx 12v dc here while cranking. If you _do_ see 12v here, but
don't see 10-11 v at the brushes, the control board is good, but the voltage
regulator is bad.
* If you _don't_ see 12v at J4/P4 pin 7 while cranking, make
the same check at P1 (the connector to the control board) pin5. If you
still don't see it here, the control board is bad.
* If you see 12v at P1 pin 5 but not at P4 pin 7, the wiring
between them, or the connection at the connectors, is bad. (For your
engineering bent, the voltage comes thru a normally open contact on K4 that
closes while cranking, and a normally closed contact on K2 that opens once there
is output from the genset.)
* If you are getting the field flash voltage at P4/pin 7 but
nothing is getting to the brushes, one last check is to test continuity from
P4/pin 9 to one brush, and from P4/pin 10 to the other brush - should be less
than one ohm, and neither should show any continuity to ground. If all this is
true, the voltage regulator is bad, and you'll have to replace it.
* If you aren't getting the 12v field flash at P4/pin 7, and it
appears to be a control board problem, try using a jumper lead to briefly apply
+12v dc toP4/pin 7 while cranking. If the voltage regulator, brushes, and
armature are OK, it should take off and start producing output - and continue
producing output as long as it is running.
* Gut feeling - based on symptoms and your measured 135 ohms
brush to brush - is that the voltage regulator is probably bad. Simplified
explanation is the voltage regulator (once the genset is running) gets
excitation voltage from the exciter winding (Q1/Q2) and monitors the output
voltage (L0/L1). It rectifies the excitation voltage and converts it to a dc
voltage that it passes to the brushes to provide a field just strong enough to
maintain the desired output voltage. If there is excess resistance in the field
circuit, the regulator has to provide a higher field voltage to get enough
current through to provide the necessary field strength. If taken to extremes,
the output devices are turned on 100% trying to provide enough field voltage to
force enough field current through the resistance to get the output voltage
where it belongs - and it doesn't take the device long to fail. If it's any
consolation to you, your new voltage regulator (although under the same part
number) is what's called a 'capped' voltage regulator -in this circumstance, it
would go to a default minimum voltage out (18v, IIRC) - they changed to this
about spec G or H.
* It's possible to check the voltage regulator with a meter
that has a good diode check function (note that if it fails any of the
following, it's bad - if it passes, it *may* be good - or bad - as this is only
a static check).
* Open the control box cover and unplug the 12-pin regulator
connector. With the meter on 'diode check', test between the following terminal
pairs, connecting the positive lead to the first pin and the negative to the
second. 5-9, 7-9, 10-9, 11-9, 12-9, 5-10, 5-11, 5-12, 5-3. Voltage regulator is
bad if any pair indicates 'short' or 'open' except for pair 5-10, which should
indicate open.
* With the regulator still unplugged, you *could* check the
windings, control board, etc by jumping 18v dc to pins 9 and 10 in the wiring
harness plug (which connect to the brushes) while you have the set running -
this should give you a nominal 120v output, or close enough to switch the
control board to run mode - then measure ac voltage between pins 2 and 3
(should be output voltage, 120v +/-), and measure the exciter winding
output between pins 11 and 12 (should be about 85% of output voltage). I
usually use two 9v transistor batteries and a 5 amp fuse to get the 18v. If it
switches to run-mode when you do this, and the output and exciter voltages look
reasonable, then everything except the voltage regulator is OK.
* Earlier (non-electronic voltage regulator) Onan generators
may lose output if the slip rings oxidize, but won't hurt anything. Later
electronic-regulator generators have a 'capped' voltage regulator - if the field
voltage exceeds what *should* be the maximum for that set, it trips a one-shot
and goes to the minimum field voltage (usually 18v) - and all current rev
replacement regulators are capped and are protected.
If system is tested by using an 18V supply, is polarity important?
* It would only be important if you were doing it with the
voltage regulator still hooked up. Since it won't be, it doesn't really make any
difference (when you get a new voltage regulator installed, the field flash
will establish - or re-establish - the desired polarity). As far as the
generator function itself, the rotor has four poles - 2 will be N and 2 will be
S regardless of which polarity you hook the 18v up.
As I didn't have any idea how long it was going to take to get
the Onan part in I ordered a new reg from Flight System's. They are building
their own design from scratch. Came with a 1 yr warranty and the reg is
repairable. Their design is a drop-in replacement. Biggest revision that can be
seen is the large cap is physically smaller and stands upright and directly
connected to the pcb. Reg came with a nice 9 page manual that included a section
on theory of operation and a block diagram. Spec sheet looks like it should be
able to handle the environment. Operation = -55&#deg to 175&#degF. The exciter specs are
250V max with 400V peak and 6A continuous @ 175&#deg and 15A peak. One of the
features mentioned was "no more start-up failures". Don't know if that is when
typ failure happens but seem to fit case when my reg failed. Flight systems says
they have some control components that Onan no longer mfrs..
If you need to adj the governor what is the correct procedure?
* On the speed/frequency issue: first, take a close look at the
genset when it is running with no load - the idle stop screw should NOT be
touching, i.e. pressing the throttle lever back against the idle stop should
lower the speed to 55 hz, and there should be visible space between the screw
and the lever. Adjust this as necessary.
* Next, with the genset stopped, unclip the governor linkage
rod from the throttle lever and check that the rod goes in the hole on the
throttle lever with the throttle lever just short of being wide open throttle.
Adjust the rod length if necessary by loosening the locknut on the other end of
the rod (where it threads into the ball and socket joint), turning the
rod into - or out of - the joint as needed, then re-tighten the locknut and clip
the rod back into the throttle lever.
* Looking at the governor mechanism, you'll see an arm
extending outwards, pivoting on a shaft coming up vertically out of the engine,
with the ball and socket joint on the end closest to you. About 2/3 of the way
down the arm, you'll see a spring extending to the right, with the left end
hooked to a link that's threaded on a screw mounted in the arm and the right end
hooked to a threaded rod that goes thru a stationary bracket, with a nut on the
other side of the bracket. This nut is the speed adjustment nut - by controlling
the tension on the governor spring, it controls the speed of the genset.
* The screw mounted in the governor arm is the sensitivity
adjustment screw - by moving the point where the governor spring is attached to
the arm, it changes the governor sensitivity. With no load, adjust the speed
adjustment nut for 62-63 hz. Apply full load - the speed should be at least 58
hz. Spec calls for 2-4hz drop from no load to full load, but in my experience,
trying for anything less than 3hz makes the gen unstable at some load levels
(whoop whoop whoop as it accelerates/decelerates but never settles on a stable
speed). If your drop from no load to full load is more than 4hz, adjust the
sensitivity screw counterclockwise by 1-2 turns, re-adjust the speed nut, then
test drop under full load again. Continue until no-load to full-load drop is
under 4hz. Do note that this presumes carburetor mixture screws are correctly
adjusted first:
* With the genset fully warmed up, apply a full 4kw load. Turn
the main adjustment inward until frequency drops slightly. Turn main adjustment
outward until frequency drops slightly. Locate the point where frequency is
highest (approx midway). From this point, turn the adjustment out
another /4 turn. Remove the load. Allow genset to stabilize for 30sec-1min, then
turn the idle adjustment screw in _slowly_ until frequency drops and engine
begins to run rough or starts hunting. Back out the idle adjustment screw as
required for smoothest running/highest frequency without hunting (may take
1/8 - 1/4 turn out from highest frequency to keep set from hunting on sudden
load removal). Test with various loads, and transitions between various
loads, to ensure stable operation under all conditions.
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