Onan CCK - Control Systems, Schematics, and Accessories; Control System Troubleshooting

CONTROL TROUBLESHOOTING
PROBLEM
PROBABLE CAUSE REMEDY
FAILS TO CRANK
1. Bad Battery Connection
1. Clean and tighten all battery and cable connections.
2. Low Battery
2A. Check specific gravity. Recharge or replace battery if
necessary.
2B. Reverse current diode (CR1) may be shorted or open causing
a drain on the battery. R2 may be open.
-- 1 -
3. Faulty Start Solenoid (K1)
3. Push start switch. Check start solenoid “SI ’ ’ t erminal voltage to
ground. When battery voltage at start solenoid “B+” terminal is
present, battery voltage should also appear at “SI” terminal; if
not. replace start solenoid.
4. Faulty Start Switch
4. Replace. Jumper solenoid (SI) terminal to ground. If solenoid
does not energize replace switch. _
CRANKS SLOWLY
1. Bad Battery Connection
1. See 1 above (FAILS TO CRANK)
2. Low Battery
2. See 2 above (FAILS TO CRANK)
CRANKS BUT
WONT START
1. Blown Fuse (F2)
1. Replace fuse (F2) on control.
2. Faulty Fuel Solenoid Or
Fuel Pump
On later models, fuel
solenoid is an integral part
of fuel pump.
2. Fuel solenoid must open during cranking and running. Check
by removing steel line from carburetor and crank engine. If
fuel solenoid is open, fuel will pulsate out of this line. If it does
not, the fuel solenoid and fuel pump must be checked
separately to determine defective part.
WARN ING 1 Use extreme care for ttlis test * D i r ect fuel
sure area is well ventilated to prevent accumulation of
gasoline fumes.
3. Faulty Ignition
3. Check to see if points open and close during cranking. If they
do not open and close, adjust and set points. Plug and plug
wires must be in good condition. Voltage at ignition coil
negative terminal (-) must alternate from+12 volts to zero volts
as points open and close during engine cranking.
4. Inoperative Choke
4. With engine not running, check choke vane movement by
pushing choke lever arm. Choke must be in closed position
with cold engine, and must be free to move against bimetal
spring. As engine warms up, bi-metal spring relaxes an fallows
choke vane to open fully. The lever will pulsate as engine
warms up. See ADJUSTMENT section.
5. Faulty Crank Ignition Relay (K2)
5. Check voltage from relay terminal “4” to ground while cranking
unit. Battery voltage should appear at this terminal. If not,
check for voltage at relay terminals “1” and “2”. If battery
voltage is present at terminals 1 and 2, but not at 4, replace
relay. If not voltage appears at terminals 1 and 2 on relay while
cranking, check wiring between start solenoid (K1) and crank
ignition relay (K2).
UNIT STARTS, BUT
STOPS IMMEDIATELY
AFTER RELEASING
START SWITCH SI
,1. Resistor R1 may be open.
2. Run Ignition Relay K3.
3. Low Oil Level
4. S3 Low oil pressure switch may be
defective.
1. Check voltage on both sides of R1. With set running voltage
should be 24-32 volts DC.
2. Check voltage on both sides of K3. Should be 12 volts.
3. Check oil level. If low or empty, refill to proper level.
4. Check S3. Switch should close with set running at 10 lbs.
minimum oil pressure.
UNITS RUNS THEN
STOPS
1. Low Oil Level
1. See 1 above
UNITS RUNS BUT
SURGES
1. Stuck Choke
1. See 5 above (CRANKS BUT WONT START)
2. Governor Not Adjusted Properly
2. Readjust governor.
rUNITS STOPS
1. Faulty Ignition
1. See 3 above (CRANKS BUT WONT START)
2. Out of Fuel
2. Refill fuel tank.
3. Low Oil Level
3. See 1 above
Remote running time
JMETER OR GENERATOR
CAMP INOPERATIVE
1 1. Blown Fuse (FI f
A
•1. Replace FI fuse on control.
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