Miller Welder/ Onan Power...

Bondo · Feb 9, 2005

Hey Guys,...... I'm trying to repair a borrowed welder,+ I'm running Blind.... No real experience with Onans,+ No Book........ Welder; Miller Bobcat, 225G, powered by an Onan, P216G-I.... History; OLD,... Welded a bead long enough to go around the World, at least once.... They had an issue with it lately(wouldn't run),+ the mechanic replaced the Coil.......It Ran Fine.... Then,... I went + borrowed it..... Ran it Maybe 8hrs.... It had fallen back to the low idle speed after the little lady had finished the bead she was doing.... As we spoke about the next series of welds she was going to lay-down,........ The Welder Just Shut Off......... I figured it was over due for Gas, so I filled it up..... Didn't take enough though.... Wouldn't Start........ Pull a plug,+ do the ground it,+ Watch for spark test... Nothing.... Testlight says it's got power to the (+) side of the coil,with the switch On,+ Blinking power on the (-) side of the coil, while Cranking........ My Conclusion,..... Bad Coil..... Wrong..... I found another New coil($56.) yesterday,+ installed it today.... Still No Start..???.... No Spark at the plugs... Just went out,+ checked somemore... Now have power at the (+)side of the coil, with the switch On... Now Do NOT have blinking power at the (-) side of the coil, while Cranking..???? There's a Capacitor with it's wire to the (+) side of the coil, It appears to be Original(looks like the condensers I used to replace with the points, Years Ago)..... Question; What's it's Purpose ?? How do I Test it ?? Will it run Without it ?? Next Question; Which Way do I turn the Muffler-Bearing to get this Dog Ganm thing to Run..????? Any Ideas.... Hints..... I'm Not Quite ready to Check the Gastank with a Match,................ Yet..................

fixin · Feb 9, 2005

Re: Miller Welder/ Onan Power...

Did the new coil come with a wire?If not change the plug wire.

SS MAYFLOAT · Feb 9, 2005

Re: Miller Welder/ Onan Power...

Bondo, is this a twin cylinder Onan? Some of the early onans had a coil with two places for coil wires. These are expensive and some people tend to convert over to a regular coil. A bud of mine had the same problem til he got the right coil. The condenser/capacitor which is the same thing charges when the points are closed and then discharges when the points open up. The condensor should be on the - side of the coil. I just went outside and checked my cubcadozer and the wire from the points goes directly to the - lug of the coil with the condensor. My engine is a kohler, but the ignition system is pretty much the basic as the rest. Good luck buddy...SS

Bondo · Feb 9, 2005

Re: Miller Welder/ Onan Power...

Bondo, is this a twin cylinder Onan? Some of the early onans had a coil with two places for coil wires.

Ayuh,........ That's the 1.... 2 Sparkplug Wires actually.... Well,.. I've got 2 Coils now.......Still No Spark.... 4 wires.... 2 High Tension,.... 1 post (+) which had/has a red wire,+ the capacitor,+ a wire that hooks/bolts to 2 other wires in a sleeve down beside the coil body(this wire extention,+ sleeve came with the new coil kit also)...... And, 1 post (-) that has the companion wire(black) that runs with the red wire.......These wires run together, down into the fan housing under the coil........ Snowing to beat H3!!.... guess it'll wait till morning....... Keep the Ideas Coming....... Thanks Guys..........

dolluper · Feb 9, 2005

Re: Miller Welder/ Onan Power...

TRY www.gmcws.org/Tech/dsimmons/onan/onan/.html#start-circuit-schematic

dolluper · Feb 9, 2005

Re: Miller Welder/ Onan Power...

Crap the link didn.t work the long route is www.gmcws.org Click on Tech Info click on Duane Simmons techinical seminar hand outs click on Onan control board operation All the schematic's there

Bondo · Feb 10, 2005

Re: Miller Welder/ Onan Power...

Thanks for the links....... I found a Great Parts Manual....... But, No Repair/ Diagnosis manuals......... I'm Still Stuck here Guys......

Bondo · Feb 10, 2005

Re: Miller Welder/ Onan Power...

^........

Bondo · Feb 10, 2005

Re: Miller Welder/ Onan Power...

^........

Bondo · Feb 10, 2005

Re: Miller Welder/ Onan Power...

^...............................................

SS MAYFLOAT · Feb 10, 2005

Re: Miller Welder/ Onan Power...

I found a bolens sight that has some schematics. You might be able to find what you are looking for here. http://Sonnys_bolens.tripod.com/diagrams.htm Scroll down past the tractors and there is wiring diagrams. If I get time today, I'll ask my buddy from Hobart if he knows. Just may have him over tonight for a few beers and shoot some pool. Then I'll interogate him. You have helped me out many times, so I'm trying to find an answer for you. I hope maybe these wiring diagrams can help you. I think you have your condensor on the wrong lug of the coil/s. It should be on the negative side. At least that is the way it is on my Kohler and in some of those wiring diagram.

Bondo · Feb 11, 2005

Re: Miller Welder/ Onan Power...

SS, I Thank You for the Help........ I'm going to switch the Cap. to the other side,+ Try It....... I can't figure out where/why I've lost the Blinking Power on the (-) side of the coil... The Starting Battery failed last night, it's charging now,+ I'll continue the Diagnosis today..... I'll also go over this link...... Thanks Again..... Bondo...

dolluper · Feb 11, 2005

Re: Miller Welder/ Onan Power...

Hay try this to test As you say, the 12V supply is in the back of the coil in the armored cable, where it is not accessible. The "negative" terminal (a misnomer in common usage) is accessible and connects to the points and condensor, and the high-voltage lead connects to the distributor cap. The coil's case is the ground. Rather than check resistance, first check for voltage at the "negative" terminal with the ignition in "run" position. With the points open, you should read some low positive voltage; with points closed, you should read no voltage -- the terminal grounds through the points. If you get no voltage with the points open, disconnect the terminal and try again. If you still get no voltage, either the coil has gone open or is not being supplied with 12V through the cable (bad ignition switch?). If you do get voltage, there's a problem with the points, condensor or distributor insulator. If the above checks reveal no fault, pull the high-voltage lead out of the distributor cap and hold it with a dry rag or other good insulator (potential exists to get a painful shock -- be careful!) so that the loose end is about 1/8" from a head bolt or other good, unpainted, ground. This should produce a fat spark upon cranking the motor. If it does, the problem is the distributor cap, rotor or plug wires. If not, you can be pretty sure the coil is bad. Also check out your ground The condensor test with ohem meter and the points must be open red+ lead to wire contector ,black - to the body of condensor it should rise in reading to indefinate as the condensor charges up if any other reading replace the condensor

dolluper · Feb 11, 2005

Re: Miller Welder/ Onan Power...

Did you have any luck

Bondo · Feb 12, 2005

Re: Miller Welder/ Onan Power...

Did you have any luck

Well,.........Sort Of......

On Friday, I brought it over to Bob, the Mechanic for the company that Owns the welder......... He had just repaired it before I borrowed it, for the Same Issues.............. Him,+ I tore into it with Test lites,+ Multi-meters,+ Had a Ball...... Both coils bench tested Good..... It's got an Eletronic trigger,.. No points.... It Seem to work,...... Sometimes......after about an hour, He decided the old girl has done a good job for the last 10 years,+ deserves some New Parts............ New Cranktrigger.... New Crank sensor..... New Capacitor......... New Voltage Regulator..... New Battery....... Should be to the supplier by Wed., I told Bob I'd go get them,+ do the install............ He said, Just go get 'em,+ He'd do the install............... OK........ It's Fun hanging around with a company with Deep Pockets....... Cuts down on Diagnosis Time...........

Then he led me out back,+ We loaded a nice Little Honda welder for the weekend...............

We got another 80 feet of steel hung today.........

Hopeing to see the Far Side of this Project Tomorrow................

ChaosDad · Feb 15, 2005

Re: Miller Welder/ Onan Power...

Bondo, just a thought, you guys did check the low oil sensor didn't you. I have had them deal me fits before ..D..

Bondo · Feb 16, 2005

Re: Miller Welder/ Onan Power...

Good Point, D...... No, We didn't check for 1,.. I Don't think it's so equipped, But I'll check it out...... BTW, The Project Was completed on Sunday......... All the brackets are hung.... Now it's time to hang 160' of batter boards, facade, fascia, whatever they're called, on the brackets,..... 5 1/2"s at a time....... I Think I'm going to use 5/4 pressure treated deck boards, hung on a 45* angle....... I don't know if it'll Look Better, But, It'll look Different than All the Others on the lake..........

Miller Welder/ Onan Power...

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