Generator Questions

[Don Higgins]

Just a follow up on my problems with an Onan 10K generator.

The generator would run for around 30 minutes and shut down. Code was always 36. We checked fuel flow and fuel pump power which was fine. Finally I shook the E1 fuel pump wire on the circuit board connector and it shut off. Checked connector and it was good. Checked the board connections and they were tight.

What is happening is the vibration from the generator is causing a connection issue on the board. Needs a board but they are $800.

So I decided to wire around the fuel pump circuit and put a separate wire to power the pump. If I had more time I would have wired it into the relays already inside the sheet metal but it appears everything is run off grounding not positive signal.

Here is what I did, put a small switch on the dash next to the generator start switch. Pulled power from the lighter circuit and put another fuse in line. Ran the wire down to the generator and connected to the fuel pump wire. So when I start the generator I also flip the switch on the fuel pump circuit. Now runs all day no more problems. Total amount the fix was $15.

When you shut off the generator you just flip the fuel pump circuit off also. Even if you don't it will still shut off.

[Rich Biebel]

Don the fuel pump power circuit on many Onan PC boards has this same problem. I have replaced countless A-1 controllers as that is what Onan calls them.

They routinely run for some time and than shutdown.....and may or may not restart. Diesels as well as gas engine units.

Your solution is fine....but obviously you have to remember to shut off the pump switch.

Sometimes the pin connections are the problem but more often it is internal to the PC board....heat seems to be the problem....The hotter it is out the more likely they are to fail.....