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Old 05-23-2011, 04:41 PM   #1
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Genset Problem Solved FYI

I see quite a few genset problems discussed on various forums so I thought I'd pass along my experience with my Onan Genset for others benefit. Since I purchased my coach in 06 I had problems with the genset. It would sometimes start normally and run just fine, other times it would start and die almost immediately. Over time I found that if I turned off the breaker at the genset the problem went away, until I turned on the breaker then it would die immediately if it was so inclined. I had it at Monaco factory service twice but each time it wouldn't fail for them. It would always have the error code 38 High Current, but would not fail while there so they wouldn't do anything for me. The last time Monaco finally relented to my pleas and sent me to Cummins NW. Same problem, had error code 38, but it would not fail for them either. They put a load test on the genset even though I told them it would either start or not and if it started they were wasting their time and mine. Naturally it started just fine for them so we both wasted a couple hours while it was on the load bank. I talked to the tech at Esco Transfer Switch, I turned off breakers, I meggered the wires between the genset and transfer switch, and on and on. I finally found that with the genset breaker on and the wires at the genset disconnected all was well. I talked to a Onan engineer at the factory and was told that it was not possible. There was nothing between the breaker and the terminal strip that would cause the problem. He went into great detail in the genset protection the circuitry in support of his position. However he too finally relented and agreed to have Cummins in Phoenix check it out. They finally dropped the genset and found a bad inverter. They repaired it under warranty because I had the records to support my time line. Sorry this took so long to explain but I thought it might be worthwhile to someone.
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Old 05-23-2011, 06:54 PM   #2
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Hi Buford B,
Can you tell us the model of Onan you have? Gas or Diesel?
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Old 05-23-2011, 07:11 PM   #3
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Onan diesel 8HDKAK-1046J
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Old 05-23-2011, 07:17 PM   #4
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Thanks for sharing Buford. Don't you just love those "NTF" problems? I wonder what it was in the bad inverter that would bring down the diesel.

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Old 05-23-2011, 07:27 PM   #5
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Over Current Fault shut down the genset. What was REALLY confusing was there is nothing but a short piece of copper wire between the breaker and the terminal strip on the genset, no current sensor, nothing. Wires attached breaker on, no joy, breaker off joy. Wires disconnected breaker on,no joy, breaker off joy. Go figure! At that point it had to be the genset.
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