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Old 03-16-2016, 02:59 PM   #1
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Onan Generator HDKAJ11451J 7500

Ok, I need to replace my inverter/controller after only 446 hours. The generator has to be pulled, because it's not on a slide. My question is as follows: Has anyone had their inverter/controller replaced? If so, was it replaced with the same controller from the same company? What's the guarantee that the new controller won't fail? Do they know why it failed & have they (Onan) corrected the problem? Thanks for any feedback.

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Old 03-18-2016, 06:37 AM   #2
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Are you replacing the generator or the inverter?

There's lot of things that can go wrong with our gensets, inverters, etc. I don't think you really gave us enough info to really know what's wrong with your particular setup.

Good luck!

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Old 03-18-2016, 09:30 AM   #3
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I have a 7.5 QD in my 2006. I am not aware of any wide spread failure of these units due to the inverter. Things break without being the result of design deficiencies.

Did you buy this coach new or used? Why do I ask?

446 hours on a 10 year old coach seems a little on the lite side to me. Is it getting regular exercise? The manual calls for 2 hours each month at 1/2 load. Give or take a few months that is close to 480 hours it isn't used for anything else. I don't know if that has anything to do with your situation but it is something to look at. (Page 11 attached file)

If you have to pull the generator consider a 1000 hour service. It ain't cheap but it is cheaper then doing it later and there are components that should be serviced/replaced at 1000 hours (or 2-5 years) depending on the components listed on the table. The 1000 hour service does a lot of parts replacement almost to the point of everything (hoses, belts...) but the motor itself. At least consider the 500 hour service. (Page 12 attached file)
Attached Files
File Type: pdf ONAN HDKAJ 7.5 QD OWNER'S MANUAL.pdf (1.37 MB, 27 views)
Don, Sandee & GSD Zeus. Guardian GSDs Gunny (7/11/15) & Thor (5/5/15)
2006 DSDP 4320, Spartan MM IFS, 2013 CR-V, Blue Ox Avail, SMI AF1, Samsung 197R Refer.
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Old 03-18-2016, 03:31 PM   #4
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I'm replacing the inverter/controller on the generator (code 46). Checked fuses, relays, grounds & all connections.
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Old 03-18-2016, 03:33 PM   #5
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Bought it used & exercise every month. I've had Onan in all my MH's over the years without problems. This is a first!
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Old 03-24-2016, 09:43 PM   #6
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I have what I believe to be a controller board failure on our HDKAJ. Without too much effort, I found a couple of shops that will repair the controller board. When I get around to fixing the Onan, that will be the path I will take. (Too many chores at the stick house after a long winter trip.)

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