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Onan BGD Burning Out Circuit Boards


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  #1  
Old 09-16-2013, 05:20:10 PM
jd2210ct jd2210ct is offline
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Default Onan BGD Burning Out Circuit Boards

Hey All,
I have an Onan BGDF 830502 C, Serial Number H910966461 Generator that burns out the control boards. Also don't hold me to the model and serial numbers as they are almost completely gone on the label. VERY hard to read. I have done some checking into these with Flight Systems and think the circuit for fuel pump, choke heater, coil, etc is the one that fry's the board. I had one go bad and purchased a new replacement from flight systems. It worked for a short time and then stopped. I purchased another one and hooked it up to the genny. As soon as I hit the start button, it fried the board and would not stop cranking the engine until I disconnected it. Any thoughts as to where to turn would be great help.
Thanks Much
Scott
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  #2  
Old 09-16-2013, 05:46:00 PM
len k len k is offline
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Default Re: Onan BGD Burning Out Circuit Boards

I don't recognize middle of model number, but looks like it's BGD model , spec #C (last letter of model #).

The first thing I'ld do is check that genset is wired as per schematic in service manual. My first guess is it's not, or something board is powering is drawing too much amps (is bad) or it's power wire is loosly shorted to ground. A real good clue to what is wrong would be to look at the board and determine what is burnt out. Just out of the blue I'm guessing a relay is welded open or closed.

I'ld look at schematic and guess whats wrong, but harddrive smoked in my other computer with gen manuals. Will take a little to reload backup cds.
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Old 09-16-2013, 05:47:03 PM
Wayne 440 Wayne 440 is online now
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Default Re: Onan BGD Burning Out Circuit Boards

It seems logical to check the "fuel pump, choke heater, coil, etc..." for excessive current draw.
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Old 09-16-2013, 06:04:15 PM
len k len k is offline
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Default Re: Onan BGD Burning Out Circuit Boards

Also check that board traces themselves are not shorting to any metal including mounting washers. Cover plate on some of these gens are metal. Also on my similar model gen there is a loose insulating peice of rectangular plastic on back of board.

I don't remember yours but some versions of this series had the board power a off-board relay that then powered pump,coil,ect. Relay could have died and someone removed it , drawing too much power from board. Some relays on some boards are only rated at 3amps.

What is gen's history?? Has gen been running normally for you in past or is it new to you?
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Old 09-16-2013, 06:13:04 PM
jd2210ct jd2210ct is offline
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Default Re: Onan BGD Burning Out Circuit Boards

OK, after checking around on this board, I believe the correct model number to be 4.5 BGDFB 3502C. This is on a bucket truck and also runs a hydraulic pump. Does anyone have any suggestions as to how to check the choke heater etc, for the proper current draw? I have a sears cheapo multi-meter, would this do the job and if so how.. I am pretty green at this generator electrical stuff. Someone will likely have to hold my hand here!!!
Thanks
Scott

Generators history is like this.. When I bought the truck, everything was working fine. One day the in bucket remote wouldn't start the generator and it began to only work once in awhile, t then it completely stopped working. Was told it was the control board, so ordered a flight systems replacement. This also worked great for a time and then failed the same way.. I ordered another replacement and hooked it up to the generator. Hit the start button and the board fried just like that and the started would not disengage until I unplugged the harness. I now have it "hot wired" by powering the fuel pump, coil, on a switch...

Thanks
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Old 09-16-2013, 06:29:50 PM
len k len k is offline
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Default Re: Onan BGD Burning Out Circuit Boards

I'ld start with the basics. Check that it's wired as per schematic first, especially it's new to you and you have not seen it run normally.

If you don't have a service manual someone along today.

Just saw your last post, getting called to dinner now. More latter.
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Old 09-16-2013, 06:36:25 PM
Daverepair Daverepair is offline
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Default Re: Onan BGD Burning Out Circuit Boards

Usually you can see what trace on the board is burnt and follow that to a pin then with the wiring diagram see what is being powered by that pin. did you save the bad boards and is it the same circuit. Send the board back to flight and I am sure they will be able to tell you, us what the burnt up component feeds. Is the board not fuse protected. If it is that is another clue.
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Old 09-16-2013, 07:11:11 PM
len k len k is offline
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Default Re: Onan BGD Burning Out Circuit Boards

Quote:
Originally Posted by jd2210ct View Post
I ordered another replacement and hooked it up to the generator. Hit the start button and the board fried just like that and the started would not disengage until I unplugged the harness.
Unplugged the harness..... if harness is to remote switch maybe that truck wiring is damaged or shorted to ground. The start stop switch grounds one of 2 wires to make it start/stop. Wouldn't expect that to fail the board though. Usually with remote wiring unplugged if gen runs normal using gen mounted switch problem is not in gen. But some commercial gens have an extra pair of wires for security lockout switch.

I need to look at schematic before I comment more.
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Old 09-16-2013, 08:02:04 PM
jd2210ct jd2210ct is offline
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Default Re: Onan BGD Burning Out Circuit Boards

I did have the remote unplugged when I installed the new board... Pretty sure the problem is not there as it burned up without it being plugged in...

Thanks

Quote:
Originally Posted by Daverepair View Post
Usually you can see what trace on the board is burnt and follow that to a pin then with the wiring diagram see what is being powered by that pin. did you save the bad boards and is it the same circuit. Send the board back to flight and I am sure they will be able to tell you, us what the burnt up component feeds. Is the board not fuse protected. If it is that is another clue.
The trace goes to pin #12 as I see it on the board which looks like it runs to what looks like a diode labeled CR3.. Not sure if this helps..

Thanks Scott
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Old 09-16-2013, 08:09:29 PM
Kpack
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Default Re: Onan BGD Burning Out Circuit Boards

Here's a old posted manual from you Len. Didn't know if you still had it. I don't know if the wiring diagram would match a comercial unit.
http://www.cumminsonan.com/www/pdf/manuals/965-0529.pdf
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