| Wiring diagram for onan 6000 control board [message #182207] |
Tue, 28 August 2012 22:14  |
OregonJimmy
Messages: 9
Registered: January 2007
Karma: 0
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Junior Member |
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Had a couple of number identifying tags fall off when working the control board. Are there any diagrams that show which wires from the connector go to which numbered board connectors?
thx
Ron Yoder
1977 Eleganza II
Oregon
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| Re: [GMCnet] Wiring diagram for onan 6000 control board [message #182212 is a reply to message #182207] |
Tue, 28 August 2012 22:20  |
Ken Henderson
Messages: 8726
Registered: March 2004
Location: Americus, GA
Karma: 9
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Senior Member |
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Ron,
If you examine the wires very closely, you should find that the connector
number are indelibly printed on them. At least they were on my
long-departed Onan before I completely rewired it.
Failing that, perhaps you'll find my redrawn schematic easier to follow
than that from the manual. The circled numbers correspond with the control
board terminals. Disregard the 4 kW title -- the 6 kW is identical.
Likewise, don't worry about the electronic ignition module -- the points,
if you need to refer to them, are adequately clear on the manual's diagram.
Ken H.
Americus, GA
'76 X-Birchaven w/Cad500/Howell EFI+ & EBL
www.gmcwipersetc.com
On Tue, Aug 28, 2012 at 11:14 PM, Ron <rony@seiu49.org> wrote:
>
>
> Had a couple of number identifying tags fall off when working the control
> board. Are there any diagrams that show which wires from the connector go
> to which numbered board connectors?
>
>
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Ken Henderson
Americus, GA
www.gmcwipersetc.com
Large Wiring Diagrams
76 X-Birchaven
76 X-Palm Beach
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| Re: [GMCnet] Wiring diagram for onan 6000 control board [message #182213 is a reply to message #182212] |
Tue, 28 August 2012 22:22 |
Ken Henderson
Messages: 8726
Registered: March 2004
Location: Americus, GA
Karma: 9
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Senior Member |
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As is my perennial habit, I failed to paste the URL I'd cut:
http://www.gmcmhphotos.com/photos/data/5813/KH_Onan_Wiring1.pdf
Ken H.
On Tue, Aug 28, 2012 at 11:20 PM, Ken Henderson <hend4800@bellsouth.net>wrote:
> Ron,
>
> If you examine the wires very closely, you should find that the connector
> number are indelibly printed on them. At least they were on my
> long-departed Onan before I completely rewired it.
>
> Failing that, perhaps you'll find my redrawn schematic easier to follow
> than that from the manual. The circled numbers correspond with the control
> board terminals. Disregard the 4 kW title -- the 6 kW is identical.
> Likewise, don't worry about the electronic ignition module -- the points,
> if you need to refer to them, are adequately clear on the manual's diagram.
>
> Ken H.
> Americus, GA
> '76 X-Birchaven w/Cad500/Howell EFI+ & EBL
> www.gmcwipersetc.com
>
>
>
> On Tue, Aug 28, 2012 at 11:14 PM, Ron <rony@seiu49.org> wrote:
>
>>
>>
>> Had a couple of number identifying tags fall off when working the control
>> board. Are there any diagrams that show which wires from the connector go
>> to which numbered board connectors?
>>
>>
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Ken Henderson
Americus, GA
www.gmcwipersetc.com
Large Wiring Diagrams
76 X-Birchaven
76 X-Palm Beach
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| Re: Wiring diagram for onan 6000 control board [message #182230 is a reply to message #182222] |
Wed, 29 August 2012 00:39 |
Ken Burton
Messages: 10030
Registered: January 2004
Location: Hebron, Indiana
Karma: 10
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Senior Member |
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The Onan flywheel alternator produces about 28 - 30 volts AC across pins 5 and 8 when the alternator is running. This voltage tells the board that the Onan is running and to keep the 12 volt DC power on the fuel pump, Ignition, and fuel solenoid (if you have one).
To check for this voltage you will need the Onan running. To keep the Onan running put a jumper between pin 5 and 9 and start the Onan. Then check for the AC voltage between 5 and 8.
If it is there then you probably have a problem with relay K2. There are several components the K# relay coil circuit that can fail including the relay.
First check the voltage between 5 and 8 and we will take it from there.
Ken Burton - N9KB
76 Palm Beach
Hebron, Indiana
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| Re: Wiring diagram for onan 6000 control board [message #182318 is a reply to message #182207] |
Wed, 29 August 2012 19:58 |
OregonJimmy
Messages: 9
Registered: January 2007
Karma: 0
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Junior Member |
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Started the engine with the pin 5 and 9 jumped (Engine kept running after the jumpers were removed). Tested for voltage from 8 to 5 got 1.75 volts.
Removed wires from upper terminals 1, 2 and 3 (without 5 and 9 jumpered) and try running again. engine still stalled.
Remove wire from board terminal 12 and try running again..engine stalled
Voltage from 11 to 10 is 13.5.
Ron Yoder
1977 Eleganza II
Oregon
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| Re: [GMCnet] Wiring diagram for onan 6000 control board [message #182321 is a reply to message #182318] |
Wed, 29 August 2012 20:23 |
Ken Henderson
Messages: 8726
Registered: March 2004
Location: Americus, GA
Karma: 9
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Senior Member |
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Ron,
You did test 5-8 with an AC voltmeter setting, right? If not, try again;
you've got to have much more than 1.75 volts for K2 to hold in and keep the
engine running.
Whether you find the correct voltage at 5-8 or not, this is a recommended
mod:
At the upper left (forward) of the Onan is a finned heat sink with several
wires to two terminals; the voltage regulator for the dedicated battery
charger. There's probably a single wire on the inboard terminal;
disconnect and tape it up. There is another wire, or more likely two, on
the other terminal; disconnect them and tape them up -- together. That
will eliminate the possibility that the regulator has failed and shorted
out the flywheel alternator.
If you DO find that the flywheel alternator is not producing sufficient
voltage to hold K2, a work-around is to wire the primary of a 110:24 vac
transformer to the 120 vac output of the Onan with the 24 vac winding
replacing the flywheel alternator to 5 & 8.
Ken H.
On Wed, Aug 29, 2012 at 8:58 PM, Ron wrote:
>
>
>
> Started the engine with the pin 5 and 9 jumped (Engine kept running after
> the jumpers were removed). Tested for voltage from 8 to 5 got 1.75 volts.
> Removed wires from upper terminals 1, 2 and 3 (without 5 and 9 jumpered)
> and try running again. engine still stalled.
>
> Remove wire from board terminal 12 and try running again..engine stalled
>
> Voltage from 11 to 10 is 13.5.
>
>
>
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Ken Henderson
Americus, GA
www.gmcwipersetc.com
Large Wiring Diagrams
76 X-Birchaven
76 X-Palm Beach
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| Re: [GMCnet] Wiring diagram for onan 6000 control board [message #182330 is a reply to message #182321] |
Wed, 29 August 2012 22:04 |
Don A
Messages: 895
Registered: October 2008
Location: Dallas, TX
Karma: 0
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Senior Member |
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" As is my perennial habit, I failed to paste the URL I'd cut: "
Just a hint Ken; when I have a cut I plan to insert in a msg I try to always paste it first. Then type whatever before and/or after.
Thanks for so many well crafted msgs sharing so much information.
Don Adams Dallas, TX
'76 26' Glenbrook, '90 Sidekick
rebuilt by R Archer, powered by J Bounds, Koba
[IMG]http://www.gmcmhphotos.com/photos/data/6109/G2.jpg[/IMG]
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| Re: [GMCnet] Wiring diagram for onan 6000 control board [message #182354 is a reply to message #182321] |
Thu, 30 August 2012 07:30 |
stradwill
Messages: 6
Registered: August 2012
Karma: 0
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Junior Member |
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Do you have a line on air bags?
---- Ken Henderson <hend4800@bellsouth.net> wrote:
> Ron,
>
> You did test 5-8 with an AC voltmeter setting, right? If not, try again;
> you've got to have much more than 1.75 volts for K2 to hold in and keep the
> engine running.
>
> Whether you find the correct voltage at 5-8 or not, this is a recommended
> mod:
> At the upper left (forward) of the Onan is a finned heat sink with several
> wires to two terminals; the voltage regulator for the dedicated battery
> charger. There's probably a single wire on the inboard terminal;
> disconnect and tape it up. There is another wire, or more likely two, on
> the other terminal; disconnect them and tape them up -- together. That
> will eliminate the possibility that the regulator has failed and shorted
> out the flywheel alternator.
>
> If you DO find that the flywheel alternator is not producing sufficient
> voltage to hold K2, a work-around is to wire the primary of a 110:24 vac
> transformer to the 120 vac output of the Onan with the 24 vac winding
> replacing the flywheel alternator to 5 & 8.
>
> Ken H.
>
> On Wed, Aug 29, 2012 at 8:58 PM, Ron wrote:
>
> >
> >
> >
> > Started the engine with the pin 5 and 9 jumped (Engine kept running after
> > the jumpers were removed). Tested for voltage from 8 to 5 got 1.75 volts.
> > Removed wires from upper terminals 1, 2 and 3 (without 5 and 9 jumpered)
> > and try running again. engine still stalled.
> >
> > Remove wire from board terminal 12 and try running again..engine stalled
> >
> > Voltage from 11 to 10 is 13.5.
> >
> >
> >
> _______________________________________________
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> Unsubscribe or Change List Options:
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| Re: Wiring diagram for onan 6000 control board [message #182358 is a reply to message #182207] |
Thu, 30 August 2012 07:52 |
JohnL455
Messages: 4447
Registered: October 2006
Location: Woodstock, IL
Karma: 12
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Senior Member |
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Spray all the connections with Caig deoxit power boost in red can. Ask anyone in electronic ind how good this stuff works. I swear by it. If bad spray, plug and exercise, remove, respray and final plug. Excess film you can blow off board with air when all done but film protects from oxidation.
John Lebetski
Woodstock, IL
77 Eleganza II
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| Re: [GMCnet] Wiring diagram for onan 6000 control board [message #182438 is a reply to message #182423] |
Thu, 30 August 2012 15:42 |
Ken Henderson
Messages: 8726
Registered: March 2004
Location: Americus, GA
Karma: 9
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Senior Member |
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Charles,
I don't have an electronics CAD program running on this computer, but a
diagram hardly seems necessary: Just connect the primary of a 24 vac
transformer into the Onan's 120 vac output and the secondary to pins 5 & 8
(disconnect the flywheel alternator that's now connected there and tape up
those leads). That's all there is to it. In fact, you could even use a
"wall wart" if you find one with 24 vac output. All that's needed is to
provide voltage to close K2. Even a 24 VDC wall wart should work if you
connect its (+) output to pin 8 and (-) to 5.
Perhaps explanation is needed: The control board locks out the start
circuit when the Onan engine is running. It knows the engine is running if
the flywheel alternator is working. If the flywheel alternator is kaput,
we can fool the control board by feeding it a sample of the voltage being
produced by the main generator -- via the 24 vac transformer.
Ken H.
On Thu, Aug 30, 2012 at 2:17 PM, Charles Wood wrote:
>
>
> ...If you DO find that the flywheel alternator is not producing sufficient
> voltage to hold K2, a work-around is to wire the primary of a 110:24 vac
> transformer to the 120 vac output of the Onan with the 24 vac winding
> replacing the flywheel alternator to 5 & 8.
>
> Not sure I really understand this...
> suggested wiring diagram maybe??(how do i do this)
>
>
>
> --
> CBWood
> 77 Kingslay
> MWC OK
>
>
> _______________________________________________
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Ken Henderson
Americus, GA
www.gmcwipersetc.com
Large Wiring Diagrams
76 X-Birchaven
76 X-Palm Beach
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| Re: Wiring diagram for onan 6000 control board [message #182509 is a reply to message #182207] |
Thu, 30 August 2012 22:10 |
OregonJimmy
Messages: 9
Registered: January 2007
Karma: 0
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Junior Member |
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Ken, great education you are giving me and others. This dialogue will become a part of my fix-it notes in the Jimmy.
Just got back out to the barn and did further testing. And here are all of the results. The only thing i havent done is hook up an external 24 volt supply. The only anamoly i found was no voltage coming from 10 to 1 with the engine running. I did confirm with an ohmeter the number 10 wire to the plastic gang connector.I did have the number 12 connection disconnected for all tests to isolate the low oil shutoff.
8 to 11 26 to 30 volts AC (Onan running)** 28.5 volts
10 to 1 greater than 10 volts DC (starter on) **NONE
9 to 1 greater than 10 volts DC (starter on) **12.8
11 to 1 greater than 10 volts DC (starter on) ** 13+
Battery charge verified, battery cables clean and functional, control board fuse (5a) OK, and oil level verified **YES
Attach jumper board terninal 9 to 5 - should hear fuel pump running ***YES
Press start switch and Onan runs***YES
Remove jumper and Onan continues to run***YES
Suspect low battery voltage between terminal 11 to 1 (with starter on)
! Must be greater than 10.5 VDC (typically 11.5 VDC***13+
Suspect [K1] starter relay or wiring faulty
! Must have greater than 10.5 VDC terminal 10 to 1 (starter on)**13+
! Temporary jumper terminal 11 to 10 and try starting (remove jumper)***no
Suspect low AC voltage (terminal 8 to 11) must be 26 to 30 VAC running **28.5
! Disable / disconnect Onan voltage regulator wiring **DONE
! Remove single wire and tape up without touching ground or other wires **DONE
! Remove double wire with adapter (keep connected) and tape up without touching ground or other wires **DONE
Fuse [F1] (5 amp) is functional **YES
[J1] and [J2] connector is functional (clean and repair) **YES
Wire terminals and board terminals are functional (no broken or shorted wires)**YES
LOP functional (not shorted to ground)**YES
Voltage regulator [VR1] is disabled - terminal 8 to 11 = 28VAC +/- 2 **YES
Ron Yoder
1977 Eleganza II
Oregon
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| Re: Wiring diagram for onan 6000 control board [message #182544 is a reply to message #182509] |
Fri, 31 August 2012 07:07 |
Ken Burton
Messages: 10030
Registered: January 2004
Location: Hebron, Indiana
Karma: 10
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Senior Member |
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| OregonJimmy wrote on Thu, 30 August 2012 22:10 |
Ken, great education you are giving me and others. This dialogue will become a part of my fix-it notes in the Jimmy.
Just got back out to the barn and did further testing. And here are all of the results. The only thing i havent done is hook up an external 24 volt supply. The only anamoly i found was no voltage coming from 10 to 1 with the engine running. I did confirm with an ohmeter the number 10 wire to the plastic gang connector.I did have the number 12 connection disconnected for all tests to isolate the low oil shutoff.
8 to 11 26 to 30 volts AC (Onan running)** 28.5 volts
10 to 1 greater than 10 volts DC (starter on) **NONE
9 to 1 greater than 10 volts DC (starter on) **12.8
11 to 1 greater than 10 volts DC (starter on) ** 13+
Battery charge verified, battery cables clean and functional, control board fuse (5a) OK, and oil level verified **YES
Attach jumper board terninal 9 to 5 - should hear fuel pump running ***YES
Press start switch and Onan runs***YES
Remove jumper and Onan continues to run***YES
Suspect low battery voltage between terminal 11 to 1 (with starter on)
! Must be greater than 10.5 VDC (typically 11.5 VDC***13+
Suspect [K1] starter relay or wiring faulty
! Must have greater than 10.5 VDC terminal 10 to 1 (starter on)**13+
! Temporary jumper terminal 11 to 10 and try starting (remove jumper)***no
Suspect low AC voltage (terminal 8 to 11) must be 26 to 30 VAC running **28.5
! Disable / disconnect Onan voltage regulator wiring **DONE
! Remove single wire and tape up without touching ground or other wires **DONE
! Remove double wire with adapter (keep connected) and tape up without touching ground or other wires **DONE
Fuse [F1] (5 amp) is functional **YES
[J1] and [J2] connector is functional (clean and repair) **YES
Wire terminals and board terminals are functional (no broken or shorted wires)**YES
LOP functional (not shorted to ground)**YES
Voltage regulator [VR1] is disabled - terminal 8 to 11 = 28VAC +/- 2 **YES
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I have seen your bug a couple of times. Voltmeter between pin 11 and the junction of C1, R1 and K2 coil pin3. I think you will find low voltage there and the relay is slow in picking up. If I remember correctly you can reach that connection by clipping on the wire part of C1 on the front of the board.
This Problem is usually R1 has changed value or C1 is leaking drawing some extra DC current causing R1 to drop more voltage than it was designed to in the circuit.
The fix is to replace C1 FIRST. If that does not bring up the voltage enough, then reduce the R1 to something less than 200.
I have fixed a couple of boards for people doing this. I have a resistor substitution box and I just clipped it in parallel across R1. The I dial up various resistances until I find one that works. When I find that value I solder that resistance in parallel with R1. I think is usually takes 250 to 300 ohms but again I do not remember.
As long as you have move than 24 VAC across pins 11 and 8, you do NOT need to install the transformer Ken H. referred to. That transformer was ONLY used if the 28VAC voltage is missing.
Ken B.
Ken Burton - N9KB
76 Palm Beach
Hebron, Indiana
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