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frankdamp's avatar
frankdamp
Explorer
Mar 11, 2013

Onan 5.5 HJAB-901A starting problem

We don't use the generator very often, other than exercising it to prevent varnish build up in the carb. It's in an '02 Georgetown.

I had used the drain screw to empty the float bowl when we parked it in early November2011. That December I had an angioplasty op and I didn't get to trying the usual monthly generator run until about April 2012. When it started then, it ran for about 2 seconds and shut down. I've been fiddling with it ever since.

Son-in-law and I really got into trouble-shooting last weekend. We found the electric fuel pump was intermittent - sometimes it would prime but most times would not. We replaced the pump with an Airtex, following the advice in an old thread on RV.net which a google search had found. We were confident we'd fond the source of the trouble, but we hadn't.

I'd like to get some ideas. It looks to us like there's somethiong in the control box that isn't working properly. The fuel pump now primes an empty carb and the engine starts. When the governor lever starts to move, the engine coughs and dies (about 2 seconds after it atsrts).

The entire generator is very clean, no signs of dirt anywhere. It has a total of 51 hours on the Hobbs meter. After it dies, as described above, we get fault code 32, which is "Engine didn't achieve correct cranking speed". We think it's cranking as well as it did when we first bought the RV, so we're beginning to wonder whether the RPM sensor is not working and the "brain" giving a "shut-down" command.

My questions are:

1. Where can I find a schematic of the innards of the controller?

2. Where is the RPM transducer?

3. Should I take the carb off and clean it anyway, just in case it's gummeed up.

28 Replies

  • I can see the choke plate move as the engine initially starts. It closes again when it quits.

    Thanks for the link to the service manual, Kpack. I'll be going outside again when it stops raining (maybe in April sometime!) to troubleshoot using the listing for FC32.

    The manual mentions a shut-off solenoid in the carb float-bowl. I can't find a reference to say whether it's powered to open or whether it's a "pulse to open, pulse to close". Does anyone know?
  • Yes those chokes will drive you crazy that's one of the first things I check I pulled on my fathers in-laws tiller all one Saturday and it was the choke I remember well after that
  • big buford wrote:
    Another quick easy check is the vacuum choke pull-off. Diaphrams go bad in them.
    Just replaced my pull-off. It would start and run fine with the exception of the first 10 minutes. OP should be able to start it with air filter off to watch the choke plate to make sure it is not staying closed.
  • Another quick easy check is the vacuum choke pull-off. Diaphrams go bad in them.
  • http://www.cumminsonan.com/www/pdf/manuals/983-0501D.pdf
    See if this will help I'm not sure about the model number check your data plate again
  • I,ll look around tonight and see if I can find a service manual sounds like it may not be making electricity like the brushes or slip rings need cleaning its a good place to start I,ll get back later . If you have a multimeter while running see if its making 120 volts.
  • 1. Onan. But their service manuals are terribly expensive.

    2. Flywheel bell housing

    3. Wouldn't hurt.

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