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Old 05-08-2013, 08:15 AM   #1
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Onan HDKAJ 7.5 KW Quiet Diesel

Fault Code: 32


Won’t crank. Fuel pump runs. Hot-wired 12V to starter solenoid winding with “RUN” button pressed cranks and starts engine and gen appears to function normally. Confirmed 12V getting past Fuse F2 (starter solenoid circuit), but not getting to starter solenoid winding connector. Concluded bad internal generator wiring or “CONTROLLER/INVERTER”. Checked local Onan parts supplier & learned controller circuit board no longer available. Must buy $2,134.93 “Controller/Inverter/Housing” package. Wired in “START” button on the dash & pray nothing more fails.

Reminiscent of our hydraulic failure last fall where a $10 set of pump motor brushes accomplished the same result as a $700 pump/motor/tank assembly from HWH.

We financially-challenged DIY full-timers are being squeezed to death!!
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Old 05-08-2013, 08:19 AM   #2
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Quote:
Originally Posted by rmeusborn View Post
Fault Code: 32


Won’t crank. Fuel pump runs. Hot-wired 12V to starter solenoid winding with “RUN” button pressed cranks and starts engine and gen appears to function normally. Confirmed 12V getting past Fuse F2 (starter solenoid circuit), but not getting to starter solenoid winding connector. Concluded bad internal generator wiring or “CONTROLLER/INVERTER”. Checked local Onan parts supplier & learned controller circuit board no longer available. Must buy $2,134.93 “Controller/Inverter/Housing” package. Wired in “START” button on the dash & pray nothing more fails.

Reminiscent of our hydraulic failure last fall where a $10 set of pump motor brushes accomplished the same result as a $700 pump/motor/tank assembly from HWH.

We financially-challenged DIY full-timers are being squeezed to death!!
I would google the part number you need. Might get some help there. Also check Amazon and EBAY. Hope you are able to get a serviceable part. Good luck
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Old 05-08-2013, 08:26 AM   #3
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You could get a "refurbished" inverter for about $1000 but as you point out that is no longer available. When my inverter failed for the 2nd time within 3 years I bought a new generator. At least I have a 3 year warranty now. Mine was a '98 model which did have problems with the rotor magnets so I was facing other expenses as well.
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Old 05-08-2013, 08:35 AM   #4
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Good job. Overcoming the "engineering" of the big green box seems to be a national pastime. The ten million 10mm screws do get old, they should have used quick pins.
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