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Old 04-08-2012, 09:38 PM   #1
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Generator Starts, Runs, Dies

On my 2003 Monaco Diplomat the Onan 7.5KW Quite Diesel generator will start, run for a minute or so then die. The coach fuel tank is 95% full and I've checked the oil and coolant levels and they are where they are supposed to be. The generator only has 101 hours run time. Suggestions?
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Old 04-08-2012, 10:45 PM   #2
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U649024....

I have a 10kw and it was doing the same thing and here's what I did.....

A) Called Onan and they told me how to get the code reading from the generator for the problem. It turned out to be a board on the electronics part of the generator. I am not that familiar with the 7.5kw so I can't tell you which board. If you call them be sure you have the year model, unit model number, and the serial number, and if you have had it serviced before and what that problem was.

B) I handled my problem this way..... I took the coach to our local Cummins service center and had them obtain the board and service the unit for me. They checked the whole unit out for me. I don't remember the exact cost but it wasn't that much for the service and the peace of mind it gave me.

C) Sometimes you can replace the part but not get to the problem. If you took it to a Cummins Service Center they can give you an estimate and you can go from there.

Good luck!

Becker
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Old 04-08-2012, 10:48 PM   #3
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As a simple check, find the fuel hose pickup if possible on top of your fuel tank and tighten the hose clamp. My generator had weird symptoms for several months and then the light bulb in my brain came on after gathering enough information and the problem has been fixed four years now.
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Old 04-08-2012, 10:53 PM   #4
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U649024.....

When you find the problem, please post the solution.

Thanks.

Becker
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Old 04-09-2012, 12:26 AM   #5
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101 hours is extremely low.

On a gas unit I would suspect a fouled carburetor.

I don't know anything about diesels so I don't know if that could be an issue.
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Old 04-09-2012, 01:04 AM   #6
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Check the circuit breakers on the gen set itself. On our PowerTech 8kw I tried to start it. It would run for 2 min. then quit. On the PT it waits 2 min for the engine to stabilize, then if no power it shuts down. With the one breaker off it senses no power being sent and shuts down. Don't know if the Onan is the same though.
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Old 04-09-2012, 07:59 AM   #7
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7.5 Quiet Diesel is computerized. First step is to look in the operators manual and learn how to read the fault code.

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Old 04-09-2012, 02:01 PM   #8
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How is the fuel filter...that's what I always check first.
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Old 04-09-2012, 07:59 PM   #9
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Have a 7.5 Onan, did the same thing.... when it did run for a minute or so it would exhaust black smoke......turned out to be a faulty fuel pump....$350 fix!!!!
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Old 04-09-2012, 09:38 PM   #10
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X2 on the fuel filter. I have run into several generators that had the same symptoms as yours. All had bad or plugged fuel filters. Get the codes. If nothing shows up, change the fuel filter next.

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Old 04-10-2012, 09:44 PM   #11
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Still Looking For Solution

Well I called a Cummins/Onan service center in San Antonio this morning and spoke to a service tech, not much help. The primary code is one flash-pause-flash-pause-flash-pause..........This is a shut down due to high temperature code. He suggested the coolant level is low or non-existant, that I should check the fill neck not the overflow for proper level. I did and the system is FULL! Every time I start it, it will run for 60 to 63 seconds and shutdown then flash the same code. I don't think it could even get to operating temperature let alone overheat in a span of 60 seconds. Guess I'll try and call Onan direct tomorrow and see what they have to offer.
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Old 04-10-2012, 09:51 PM   #12
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I hate to say it but your situation sounds very much like the one in this thread: Onan Diesel 7500 won't start

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Old 04-10-2012, 09:59 PM   #13
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Cliff,

The fault code indicates you have a bad water temperature sensor. The bad news is unless you're lucky and your coach has the generator on the tray or provides enough room to get the covers off and reach the sender, you have to drop the generator out of the coach to replace it. This is a relatively common problem. I am aware of several folks that have had this problem. You can drop the generator with some help, but it's not easy.
BTW, while you're taking care of this issue, I recommend you change the "fan" belt also.

Good luck.

Jim
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Old 04-11-2012, 08:47 PM   #14
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Much thanks for all your comments and suggestions!! After speaking with two different Onan reps and one RV service tech the consensus is a bad temp sensor or bad control board. Of course they all want me to bring it in so they can be sure. Not sure if I want to attempt to pull the unit myself or not, will take a good look at what it will take and make a decision this weekend. Probably end up taking it to a Cummins/Onan shop.
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