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Old 03-20-2019, 06:57 PM   #1
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Any Onan experts out there?

My Onan DKD generator won't turn over unless I bump the control box on top. Once I bump any part of it the starter will engage, and it might crank 9 or ten times before it does it again. I thought I had a bad relay & replaced it, but it didn't help. Any ideas?
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Old 03-20-2019, 07:09 PM   #2
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Sounds like a bad or corroded connection
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Old 03-20-2019, 08:08 PM   #3
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Sounds like a bad or corroded connection
Everything appears clean & tight, but I can tap any relay or even the outside of the box & it'll fire off. I'm pulling my hair out! Gotta be something simple I'm missing!
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Old 03-20-2019, 08:43 PM   #4
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Everything appears clean & tight, but I can tap any relay or even the outside of the box & it'll fire off. I'm pulling my hair out! Gotta be something simple I'm missing!
Ground point of box ?
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Old 03-21-2019, 05:37 AM   #5
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Ground point of box ?
Clean & tight. There's 3 small relays in the back, and one large solenoid. When it won't turn over there's no power on the small wire on the large solenoid. As soon as I bump anything I have power on it when start switch is on. I've already replaced the small relay that clicks when start switch is on. I'm thinking Jack Daniels or Jim Beam..........
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Old 03-21-2019, 06:52 PM   #6
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DEAR DR DANIELS, Just call me JACK!

Some solenoids have to be grounded as some components on ONANs are on rubber mounts. Try using a "VOLT METER"....hook it up and see the voltage reading...before you give it the BUMP! I assume you mean, you bang it ...or jolt the box assembly.
ELECTRICITY..has to have two components to work....A + POSITIVE and a NEGATIVE ground to complete the 12 volt circuit. I will guess and say you have a dirty or loose ground on your system. Take a Alligator clip and hook it directly to your battery negative source and the other end to a Known good ground connection inside the box you are banging on. That will pretty much discount having a bad ground or connection. Any place you are measuring the voltage...should have a reading that is somewhat close to full battery voltage. Good LUCK. JACK also said...." I DON'T KNOW WHY MY HEAD HURTS TODAY? I DIDN'T USE IT LAST NIGHT??!"
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Old 03-21-2019, 07:09 PM   #7
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Your DKD has an inexpedient Battery for the Genset only - Check that first -Voltage at the battery and Voltage while cranking- If it drops below 11 volts while cranking your Battery is done !
I have 2 DKD's one in the Old Eagle on one for a spare and they are bullet proof as long as you service them correctly !
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Old 03-22-2019, 06:38 AM   #8
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Here's a shot at one of my control boxes- as you can see there is a Solenoid in there- Maybe a loose connection is causing your problem
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Old 03-22-2019, 05:13 PM   #9
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Here's a shot at one of my control boxes- as you can see there is a Solenoid in there- Maybe a loose connection is causing your problem
So far no loose connections found, but I'm still digging! My control box looks just like yours except I have 3 small relays where I only see 2 in your photos, shown at the bottom below the start solenoid. The left relay clicks when you hit the pre-warm switch, center I can't hear, & right clicks when you hit start. I've replaced it, but nothing has changed. Battery is new, & spins it over good when I tap it so low voltage shouldn't be the problem. I think I'm going to disconnect the trigger wire from the start solenoid & try tracing it back to it's source. Or just keep a hammer handy!
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Old 03-22-2019, 05:26 PM   #10
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Check all of the wire connections on the circuit board - sounds like something is loose somewhere - disconnect the battery while your in that box .
There is a diagram inside of the box cover
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Old 03-22-2019, 05:43 PM   #11
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Check all of the wire connections on the circuit board - sounds like something is loose somewhere - disconnect the battery while your in that box .
There is a diagram inside of the box cover


I have all if the manuals if you need them !
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Old 03-22-2019, 06:08 PM   #12
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I have all if the manuals if you need them !
I may be hollering at you! The diagram inside my cover is pretty much gone. Another question for you. My fuel gauge didn't work, the sender wire was GONE! But I found where it came from a junction box under the forward hood it now it works fine. I just noticed when I start the generator the fuel gauge comes on without the coach ignition switch being on. Is this normal?
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Old 03-22-2019, 06:34 PM   #13
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I think your messing with me now !
There is no fuel gauge connected to your DKD - But that's similar to a ground issue somewhere.
Is your DKD self contained or a split system ?
Self Contained is a DKD usually installed in a side compartment with the radiator attached to the Genny.
The split system install is usually in the front of the MH on a slide out with a remote mounted Radiator mounted on the side of the MH.
Also go to Lowes or your local box store and buy a Kill a watt voltage monitor- Every MH owner should have one to occasionally monitor the Genny !
https://www.amazon.com/P3-P4400-Elec...72288073&psc=1
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Old 03-22-2019, 08:16 PM   #14
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I think your messing with me now !
There is no fuel gauge connected to your DKD - But that's similar to a ground issue somewhere.
Is your DKD self contained or a split system ?
Self Contained is a DKD usually installed in a side compartment with the radiator attached to the Genny.
The split system install is usually in the front of the MH on a slide out with a remote mounted Radiator mounted on the side of the MH.
Also go to Lowes or your local box store and buy a Kill a watt voltage monitor- Every MH owner should have one to occasionally monitor the Genny !
https://www.amazon.com/P3-P4400-Elec...72288073&psc=1
Not messing with you! And I'm thinking there must be some fuel gauge connection because there's a low diesel fuel light on my overhead control panel, right by the start/kill switch.
Mine must be a split system. It's mounted in the front of the coach between the frame rails with a radiator in front, but it's definitely not a slide out! Access is through a hatch between the front seats with not much room for an old fat boy like me!
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