Onan Homesite 6500 Service Manual
I was searching the web for information on a recently acquired Onan generator when I stumbled on this forum. There appears to be a tremendous wealth of knowledge here and a good community as well! Hopefully somebody here can help steer this project to completion. I recently acquired an Onan Commercial 6.5 generator. 6.5NHD – FD/1M.
I have an Onan 6500 homesite generator. It was working. Cummins onan homesite 6500. I have just had my onan micro quite 4000 repaired by an onan service.
Serial # D980728985. It was a very good deal, however it was missing some important components. Muffler – no big deal. Start/stop switch control board – not as easy.
My understanding is this was installed on a service truck and the original control board was remotely mounted in the cab and subsequently lost. I stopped by the closest Cummins/Onan dealer and they were less than helpful. To make a long story short, after an hour at the counter and some surly attitude, they gave me a price of $750.00 for the parts I need. On to Plan B. I traced each of the wires back to their origin and I have almost everything figured out.
I have assembled an “old school” controller with switches and relays that perform the same basic functions. The generator starts and runs. The only problem is that it doesn’t make electricity.
There is one wire in the group that I have not been able to identify yet. The previous owner has it tagged “AVR BAT P4.3”. My guess is that wire supplies exciter voltage to the generator. I did purchase a copy of the service manual.
Unfortunately it is a little vague around the area of the control board. As this project is nearing a successful conclusion, I thought I would seek some expert advice before testing my hypothesis. I would hate to see smoke pour out of it now. While this motor might make an unusual power plant for a log splitter, it is more valuable to me as a generator. I work with low voltage control circuits and residential house wiring every day.
Power generation is a little out of my arena. This generator has all the output wiring I would expect – 2 black wires, a white, and a green wire. It also has a black wire with a yellow stripe that I was not expecting. Once completed this will primarily be used for residential backup power – charging my battery bank and running the well pump when utility power is unavailable. Any assistance or guidance you can provide would be greatly appreciated.
Service Manual for this Unit IS: Onan #965-0500. Parts Manual is Onan # 940-0229. You are aware that this Genset left the Factory as a 120/240 Vac 3 Phase Unit, RIGHT? Also a note on that: From the Manual, it looks like MAYBE, it is a 12 Lead Genend, and could be rewired for 120/240 Single Phase. You really need the Service Manual to see exactly what is missing, from your Unit. The pictures really 'don't tell the tail' on what exactly is missing.
If the controller PCB is missing, then the costs for a replacement are considerable, especially from Onan. You might look around for a USED one from one of the Distributers, or from one that is Parted Out. Service Manual for this Unit IS: Onan #965-0500. Parts Manual is Onan # 940-0229. You are aware that this Genset left the Factory as a 120/240 Vac 3 Phase Unit, RIGHT? Also a note on that: From the Manual, it looks like MAYBE, it is a 12 Lead Genend, and could be rewired for 120/240 Single Phase.
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You really need the Service Manual to see exactly what is missing, from your Unit. The pictures really 'don't tell the tail' on what exactly is missing. If the controller PCB is missing, then the costs for a replacement are considerable, especially from Onan. You might look around for a USED one from one of the Distributers, or from one that is Parted Out.
For Control Boards, what about Flight Systems or A.S.A.P (partsfortechs.com) for reasonably priced equivalents? Good luck in your project. No, there is no Extended Stack for this Genset.
It is a Standard 120/240 Vac 3 Phase 4 Wire Center-tapped Delta. You can only pull 2/3 Max Rated Load from the 120/240 SinglePhase C15.onnection. 15.6 Amps/Leg. Are all of these generators 3 phase? 6500 commercial models.
Or is it just this one. Also why on earth would a service truck need or even want 3 phase. Saws drills air compressors just about every tool in a service truck is single phase 110.v maybe 220 for a welder but when I think of 3 phase I see Mills lathe.
Most of these generators are 120 only or 120/240 single phase. Occasionally you see a three phase unit. You have to read the label and know what you are buying BEFORE spending your money. This is the sort of thing I would consider a $50 parts machine. It had at least three strikes against it. It was three phase.
It was missing parts, and as the original poster found out, Onan is VERY proud of their parts. It was not capable of being test run before purchase, which could have concealed more EXPENSIVE damage. In other words, it wasn't a generator, it was a PROJECT.
Many times on Craigslist you will see these motor home or bucket truck pulls with the description: 'Ran before it was removed' or 'ran last time it was used'. I always tell the owner 'I don't care if it ran before it was removed. You want my money NOW. If I can't see it run, and produce power, NOW, as far as I'm concerned it's a parts machine, worth somewhere in the $50 to $100 region'. From the manual: The control board, in addition to all the normal stuff it's doing, is also getting input from the PMG (permant magnet generator) and 120VAC lines. But I'm guessing all it's doing with those is lighting the LED idiot lights, other control boards don't have those inputs.
Onan Homesite 6500 Manual
Other Onan gen (NHE,etc) control boards don't have/use these inputs. I always figured if I had to I'ld adapt a control board from a ONAN 7NHM gen, a later board like gen spec H uses (service manual 965-0531B page B-8). I have the NHM and board looks pretty simple, less to go wrong. The NHM also has an electronic governer. You'ld just have to make sure the oil pressure sensor is the type that is open when running and closed when not running.( they come both ways). Skimming the manual, on yours the PMG input to control board is used to shut off starter when engine starts, even if button is held down.
Onan Homesite Power 6500 Service Manual
The NHM board does this also, but in a different way. I think it uses the oil pressure switch or governer as an input, have to read the NHM manual. ONAN 7NHM control board is arround $100 at Flight Systems, a very good company.