- Onan 4500 Emerald Commercial Genset Manual Transfer Switch
- Onan Emerald 111 Genset Manual
- Onan Commercial 4500 Generator Specs
The Quiet Diesel Series models are the heavy-duty choice when low noise and low vibration are required. Their revolutionary design makes these generator sets up to 15 dB(A) quieter than other diesel-powered generators, and quieter than most gasoline sets. The units are totally enclosed, including cooling, muffler and intake systems. The Owner’s Manual that comes with every new Cummins Onan generator. Our promise to you is to continue to provide the best performing RV generators and the largest, best-trained service organization in the business. By following the tips contained here and having your Cummins Onan Authorized. To get started finding Onan 4500 Commercial Generator Manual, you are right to find our website which has a comprehensive collection of manuals listed. Our library is the biggest of these that have literally hundreds of thousands of different products represented. The latest from Cummins Inc. Designed to go wherever you do, the new advanced portable inverter and dual-fuel generators by Cummins, bring together efficiency, durability and performance to deliver three of our most versatile and reliable products ever, all backed by the Cummins 24/7 global support network to ensure that you’ll always have power for when you need it most. This generator I got had a horrible misfire. The video does not do it justice but it was popping, jumping, shaking etc really bad. Pulled the plugs and found.
Onan Manuals
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 ofthe information below will only make sense and or apply to my specific case so don't let that confuse you if youtry 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 Emerald4kw)
(WEBMASTER COMMENT: this information is specific to the model listed - your particular model mayhave different specifications and wiring connections. Therefor this article is intended for general informationonly. Before doing anything, verify your model number and specifications)
Also, check the oil level first - There is an oil pressure sensor that shuts down the genset if the oil pressure drops. When the start button is pressed it bypassesthe oil pressure cut off circuit and the engine will run only if the button is pressed in. Check the wire to the oil pressure sensor - the sensor is located under the cover near the oil filter. It may have been knocked off.
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 thenegative 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 voltageregulator is bad. * If you _don't_ see 12v at J4/P4 pin 7 while cranking, make the same check at P1 (theconnector to the control board) pin5. If you still don't see it here, the control board is bad. * If you see12v 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 thefield flash voltage at P4/pin 7 but nothing is getting to the brushes, one last check is to test continuity fromP4/pin 9 to one brush, and from P4/pin 10 to the other brush - should be less than one ohm, and neither should showany continuity to ground.
If all this is true, the voltage regulator is bad, and you'll have to replace it. * If you aren't gettingthe 12v field flash at P4/pin 7, and it appears to be a control board problem, try using a jumper lead to brieflyapply +12v dc toP4/pin 7 while cranking. If the voltage regulator, brushes, and armature are OK, it should take offand 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 regulatoris probably bad. Simplified explanation is the voltage regulator (once the genset is running) getsexcitation voltage from the exciter winding (Q1/Q2) and monitors the output voltage (L0/L1). It rectifies theexcitation voltage and converts it to a dc voltage that it passes to the brushes to provide a field just strongenough to maintain the desired output voltage.
If there is excess resistance in the field circuit, the regulator has to provide a higher field voltage toget enough current through to provide the necessary field strength. If taken to extremes, the output devices areturned on 100% trying to provide enough field voltage to force enough field current through the resistance to getthe 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 agood 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 thesecond. 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 dcto pins 9 and 10 in the wiring harness plug (which connect to the brushes) while you have the set running - thisshould give you a nominal 120v output, or close enough to switch the control board to run mode - then measure acvoltage between pins 2 and 3 (should be output voltage, 120v +/-), and measure the exciter winding outputbetween 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 whenyou do this, and the output and exciter voltages look reasonable, then everything except the voltage regulator isOK. * Earlier (non-electronic voltage regulator) Onan generators may lose output if the slip rings oxidize, butwon't hurt anything. Later electronic-regulator generators have a 'capped' voltage regulator - if the field voltageexceeds 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 willestablish - or re-establish - the desired polarity). As far as the generator function itself, the rotor hasfour 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 FlightSystem's.
They are building their own design from scratch. Came with a 1 yr warranty and the reg is repairable. Theirdesign is a drop-in replacement. Biggest revision that can be seen is the large cap is physically smaller andstands upright and directly connected to the pcb. Reg came with a nice 9 page manual that included a section ontheory 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 failurehappens but seem to fit case when my reg failed. Flight systems says they have some control components that Onan nolonger 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 - theidle stop screw should NOT be touching, i.e. pressing the throttle lever back against the idle stop should lowerthe 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 therod goes in the hole on the throttle lever with the throttle lever just short of being wide open throttle. Adjustthe rod length if necessary by loosening the locknut on the other end of the rod (where it threads into the balland socket joint), turning the rod into - or out of - the joint as needed, then re-tighten the locknut and clipthe rod back into the throttle lever. *
Looking at the governor mechanism, you'll see an arm extending outwards, pivoting on a shaft coming upvertically out of the engine, with the ball and socket joint on the end closest to you. About 2/3 of the way downthe arm, you'll see a spring extending to the right, with the left end hooked to a link that's threaded on a screwmounted in the arm and the right end hooked to a threaded rod that goes thru a stationary bracket, with a nut onthe other side of the bracket. This nut is the speed adjustment nut - by controlling the tension on the governorspring, it controls the speed of the genset. *
The screw mounted in the governor arm is the sensitivity adjustment screw - by moving the point where thegovernor spring is attached to the arm, it changes the governor sensitivity. With no load, adjust the speedadjustment nut for 62-63 hz. Apply full load - the speed should be at least 58 hz. Spec calls for 2-4hz drop fromno load to full load, but in my experience, trying for anything less than 3hz makes the gen unstable at some loadlevels (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 by1-2 turns, re-adjust the speed nut, then test drop under full load again. Continue until no-load to full-load dropis 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 frequencydrops slightly. Turn main adjustment outward until frequency drops slightly. Locate the point where frequency ishighest (approx midway). From this point, turn the adjustment out another /4 turn. Remove the load. Allowgenset to stabilize for 30sec-1min, then turn the idle adjustment screw in _slowly_ until frequency drops andengine begins to run rough or starts hunting.
Back out the idle adjustment screw as required for smoothest running/highest frequency without hunting (maytake 1/8 - 1/4 turn out from highest frequency to keep set from hunting on sudden load removal). Test withvarious loads, and transitions between various loads, to ensure stable operation under all conditions.
Onan Generator Troubleshooting; 13 Tips for RV Generator Repair
Onan is known for its standby generators. However, they also make portable generators, especially those that go in RVs. Many Onan generator models can run on gasoline and liquid propane. Their generators are typically compact and relatively quiet. They often sell generators in portable shells that protect them while muffling the sounds it makes.
Their generators regularly come with intelligent control boards capable of self-diagnostics, while most units have an integrated design that is incredibly easy to connect to your RV. That is aside from the fact that Onan generators are often built into the RV by the manufacturer.
Here are our top 13 tips for getting the most of out your Onan generator troubleshooting fixed.
Onan is one of the top selling generator brands in the United States. However, the brand has been picked up by Cummins. That’s why you now see products listed as Cummins Onan or Cummins part number Onan.
This means that you may have to search for the Onan part number in the Cummins inventory listed on a website. That’s especially true for consumable parts like spark plugs and air filters.
For example, the Onan generator manufacturer’s home page is now www.cumminsonan.com.
If your Onan generator isn’t running, it may be because fuel levels are too low. While some RV generators will run until the fuel tank has nothing but fumes, the Onan models tend to stop working when you’re down to a quarter tank. The units that do this are the ones drawing from the gas tank.
The intent is to ensure that the RV isn’t stranded because you have no gas in the tank. In the future, top off your RV gas tank so that it never runs low. And know that the generator will shut down if the gas gauge is around one quarter.
Note that you can really run into problems if the gas tank float is off, so the generator turns off though you have a half-full tank.
Onan generators have a number of built-in safety features. One of these is the fuel cut-off switch so you don’t use all your gas running power though it would leave you stranded on the side of the road.
Another is the low oil cut-off. If the generator is cutting off, check the oil levels. You can avoid problems by making sure the oil tank is full. It also means that an oil leak in the generator can kill it well before the unit suffers damage.
If the safety feature trips and the generator is giving you an error code, look it up before assuming that resetting the generator is all you need to do. For example, issues that make a generator run rough could be deal with temporarily, but the long-term damage will destroy the generator.
Onan generators are among the smartest on the market. They can self-diagnose issues. However, it won’t tell you outright it thinks the oil is low. Instead, it flashes codes to indicate the problem.
One solution is to check the manual. What if you don’t have the manual? Then you can go to www.cumminsonan.com and look up the error codes. Even the error codes for older and rare Onan generators can be looked up on that site.
Tip 05. Know the maintenance needs of your Onan generator.
Onan 4500 Emerald Commercial Genset Manual Transfer Switch
Onan has made a number of design changes that simplify maintenance. For example, the Onan 4K generator doesn’t have an oil filter. On the other hand, you have to use the right oil and never use old oil to keep the generator from clogging up.
Know the right level of oil, because over-filling will cause the generator to shut off just as too much would. Know where you would access the carburetor if you need to clean it and where you access other points required for maintenance.
In some cases, you have to restart the line breaker in the RV to get the power going after you’ve done maintenance on the generator. This is because of the safety features built into the RV after you’ve lost power, even if it was because you disconnected the battery while working on the generator.
Always know where the circuit breakers and other electrical panels are so that you can reset or repair things as necessary.
Tip 07. Know the benefits of a dual fuel generator.
Do you have a dual fuel generator in your RV? For example, some Onan generators can run off both gasoline and liquid propane. This allows you to conserve gasoline when you’re away from civilization.
And it allows you to switch to another fuel source to see if the root cause of it shutting down is a low gas level. For example, switch to propane if the gas tank is getting low. And consider carrying extra propane tanks in addition to gas cans.
Do you need extra air conditioning in your RV to stay comfortable? Onan generators don’t have the same peak load / surge capacity as some inverter generators. This means you should turn on the RV generator before you turn on the roof-top AC to avoid tripping electrical safeties.
And don’t try to turn on too many things at once, since that can cause surges that trip the safety measures like the over-voltage protection.
Onan generators are often powerful. For example, you can find units that can power one or two air conditioners. However, they don’t always have excess capacity. Know how much power the generator can supply and the load everything you’re running in the RV will draw.
For example, you may be able to run the air conditioner at full blast and the refrigerator at the same time but not the microwave, too.
The 7000 watt Onan RV generators may seem like they can run everything in the RV, but you can cause it to trip safeties if you try to do too much. The over voltage protections in particular tend to engage when you walk into the RV and turn everything on.
Onan itself is known for high quality generators. Onan is relying on network of contracted dealers to provide service for most of their RV generators. Service levels vary between mechanics and RV shops.
Do your research before you bring in your RV for service. And verify that the RV shop is experienced working with Onan Cummins generators. Just because they can work with other brands doesn’t mean they know how to repair Onan Cummins generators.
Onan Emerald 111 Genset Manual
While the Onan RV generators are an industry standard, not all service providers can and will have replacement parts in stock.
Tip 11. Understand the value of various labels and certifications.
In most cases, your Onan generator is USDA Forest Service Approved. Do you know what that means? Why yes, Mr. Forest Ranger, we are allowed to run the generator in our RV while we’re parked in sensitive national parks, because we know it can’t accidentally spark a wildfire.
Nearly all Onan generators also meet the National Park Service sound level requirement. That is 60 decibels of noise or less at a distance of fifty feet. These rules may allow you to run your generator later at night in RV parks with noise limits, too, but you should know their rules rather than assuming you’re already compliant.
Onan warranties depend on the application. For example, it is common to see a three year or 2000 hour warranty on an Onan generator. If you’re running it nearly all day every day, that means you’ve blown through the warranty in a year.
Another issue is the application. The Onan generator’s three year limited warranty is when it is in the RV and only powering the RV. If you take it out of the RV and use it to provide backup power for your home, the warranty is two years at most.
Onan Commercial 4500 Generator Specs
If you put an RV generator in your shed and use it as a backup power source, it will then have the two year non-RV warranty in place if it applies at all. Find out what the warranty will be from the supplier.
We already mentioned that Onan generators sometimes don’t have oil filters. They generally have fuel filters. However, those are not always easy to replace and can be expensive. This makes using quality consumables.
Don’t put old gas or watery gas in your generator. Only use high quality gas, though this doesn’t mean you have to use premium gasoline.
This also means you’ll get extra mileage out of the generator if you use a good fuel injector cleaner periodically. While that adds to the cost of your maintenance routine, it is a necessity because Onan generators are designed to run smoothly on high quality intakes.
If you did use cheap gas or the wrong fuel, clean everything immediately to avoid problems.
The odds are high that your RV generator is an Onan Cummins or original Onan model. Know how to sustain, maintain and repair common issues with the generator to minimize trips to the mechanic and maximize the running life of the most important equipment in the RV aside from the car motor.