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Old 12-09-2019, 10:24 AM   #1
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Onan 7500 fault code 38

2002 Alpine, whenever it is raining out, driving or not, I get a code 38 on the onan 7500. I have read quite a bit about folks having the issue when driving in the rain, but mine is just parked on my rv pad.

I looked at the junction box with the wire nuts and its all dry and connections are tight.

This is with no load on the generator at all, nothing on at all in the coach. But I turn off the gen breaker and itll run.

Any other suggestions to check out and look at?
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Old 12-09-2019, 12:22 PM   #2
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Code 38----Overcurrent (too much load)
If nothing is running then engine performace may be hindered


Have you gone thru your AC Panel ---turned ALL circuit breakers OFF
Started Gen

No Fault code..close AC CBs one at a time
To verify issue is back at Generator and NOT output load related


No Code 38 with gen breaker Open then engine componets need checked

Fuel Line degenerating
Carb gummed up

Air Filter water soaked
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Old 12-09-2019, 12:55 PM   #3
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It is a good idea to check the all your grounds and bonds - both chassis and in the panels. Loose grounds = hi resistance
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Old 12-09-2019, 12:58 PM   #4
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I have turned off all circuit breakers in the coach when it is doing this issue and it still occurs when the gen circuit breaker is on. Runs for a bit then shuts off.

If the gen circuit breaker is off, itll run well.

Saturday was raining out and i had this issue and tried the above.
Sunday was sunny out and it ran just fine with all circuit breakers on and under a load.

i have had this issue in the past too. And i found it odd that it was only when it was wet/rainy outside....until I started searching and noticed others had this issue too. The generator was just serviced this summer. I will check the air filter and also found another post stating he taped off the area where the circuit breaker is on the gen and that fixed it. Going to reseal the front slide too.
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Old 12-09-2019, 01:06 PM   #5
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Originally Posted by andy29847 View Post
It is a good idea to check the all your grounds and bonds - both chassis and in the panels. Loose grounds = hi resistance
i have checked the wiring and grounds already. Think i will take the wire nuts off in the junction box and redo those, but the junction box itself is completely dry. they are all tight but maybe i will redo them and see if it helps.
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Old 12-09-2019, 07:54 PM   #6
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Another place to check would be your transfer switch.

Wires tight and not burnt or defective relay?
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Old 12-10-2019, 01:35 AM   #7
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checked all the wiring, everything looks good. checked the ground on the back and it is tight. the positive cable had a little chaffing on the wire cover, but very very minimal so i rerouted that cable and taped over that area. air filter was completely dry and new since it got serviced this summer

i did notice that when it rains, water drips through the seam on the front slide right onto the front panel where the circuit breaker switch is. I got some thick plastic and some gorilla tape and covered that whole panel up. We shall see what happens, supposed to rain tomorrow.
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Old 12-12-2019, 01:11 AM   #8
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It has poured the past two days and after taping up the panel on front of the gen set it keeps running under heavy rain. So Iím thinking water was getting in through the circuit breaker switch and causing it to shut down? Thatís all I can think of.
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Old 12-12-2019, 03:44 AM   #9
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Old 12-12-2019, 05:50 AM   #10
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…..another potential source of moisture in that area is condensation from the dash AC evap coil and piping. Recommend "taping" the top seam of the genset cabinet across the entire cabinet....I used a pliable, putty-like taping material to do the job--easily removed and replaced when access to the inside of the cabinet is needed...
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Old 12-12-2019, 10:39 PM   #11
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Ö..another potential source of moisture in that area is condensation from the dash AC evap coil and piping. Recommend "taping" the top seam of the genset cabinet across the entire cabinet....I used a pliable, putty-like taping material to do the job--easily removed and replaced when access to the inside of the cabinet is needed...
I used gorilla tape along the whole seam and some thick plastic with the tape over the panel and did exactly that. Also ordered some new foam seal for the gen slide. Seems to be working so far.
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