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Old 08-02-2015, 11:37 PM   #1
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Onan 8k diesel generator

We have an Onan 8k quiet diesel genset in our motorhome. Model 8HDKAK11451K (Ser # A070015168) The unit has just under 800hrs on it. Never had an issue of any kind till now.
It worked for us 2 weeks ago...no problems. Coolant is full. Oil is full. Serviced regularly.
We store our motorhome plugged into shore power to keep batteries charged and the fridge cold.
Yesterday while walking past the front of the motorhome, i noticed a "clicking sound."Upon further investigation, i found the the generator fuel pump running. The light on the dash switch and the light on the generator switch illuminated. Holding down the switch (both dash and generator) in either direction does nothing. It wont crank....and the fuel pump just continues to run when the "stop" side of the switch is pressed. I cant get anykind of code to flash. Only way to shut off the fuel pump is to press the house battery disconnect switch at the the entry door and take away the 12v.

Anyone happen to have an idea or suggestion? -Thanks
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Old 08-02-2015, 11:57 PM   #2
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Do you have auto start feature? If so, that's where I would look. Just a guess as I haven't heard of this.
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Old 08-03-2015, 05:32 AM   #3
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No autostart...that i am aware of. Oh...and there is fuel in the tank. I pulled the hose off just to make sure there was fuel at the inlet and we have a full hose stream. I was sort of thinking the fuel pump may be shot. If the injection pump sees no pressure, there may be a pressure sensor that will not allow voltage to the starter. Therefore the fuel pump just runs and runs...but that is just a stab in the dark. (...no pun intended..lol)
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Old 08-04-2015, 08:54 AM   #4
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Hmm.. I would suspect a wiring issue, most likely between remote switch and the generator, or the remote switch. It sounds like the fuel pump is "priming". This is normally accomplished by HOLDING the STOP switch down for one minute.

Disconnect the wires from your switch and see if it continues. If so, you have a short in the wiring between switch and gen. If disconnecting the wires makes the fuel pump stop, then most likely the switch is bad.
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Old 08-05-2015, 08:23 AM   #5
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Well...update time. I wish it was as easy as a switch or corrosion.
I found a service manual (online) and found the issue listed in the "Troubleshooting" section. I followed the corrective action steps and verified both switches (and wiring) are functioning as they should. The last instruction listed is "Replace the controller assembly"
Basically the problem lies somewhere in the control board. After finding the Onan part number in the manual (another online manual) we learn that the control board is "not a field serviceable part." The entire assembly...including the inverter must be purchased. (cost in excess of 2500.00) Additionally, we also need to drop the unit out of the motorhome to allow full access.
Needless to say I am pretty upset/disappointed that we have once gain fallen victim and have yet another example of the "computer controlled throw-away society" in which we now live. I am grateful that I have the ability to do some of the work myself...although I will have to work on garnering enough motivation to do so.
I plan to contact some of the repair companies (flight services ect) and see if it is possible to ease the hit.

Can anyone offer other suggestions for control board repair companies? Anyone willing to share there experiences with said repair companies? Should I bite the bullet and buy the "genuine Onan" assembly?
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Old 08-05-2015, 10:59 AM   #6
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Bummer. We had to replace our inverter section 3 years ago due to an inverter overload fault. While it was out, we had all the belts and hoses replaced too, and I think the total bill was around $3400 at Cummins Coach Care in Houston. I have no experience or knowledge about other repair options, so I have no advice to give there. Please keep us posted how you make out.
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Old 08-05-2015, 11:25 AM   #7
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Another question. Were you able to find a Cummins part number for the control board? If so what is that part number?
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Old 08-06-2015, 10:03 AM   #8
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Part numbers were found in the parts manual. So yes, there is an operators manual, a service manual, and a parts manual. The parts manual lists the inverter/control assembly as PN 300-5295-96. Cummins dealer says that part number has been superseded by PN 300-6058-02. I am hoping that with a new part number comes some upgraded and more robust components, but Im not holding my breath. The cost of the replacement assembly is near 2k. (depending on where you buy) Despite the fact that kind of outlay means I'll be eating peanutbutter sandwiches for lunch for the next several months...Im really nervous about replacing parts that may give me the similar trouble in the future. At that point, we may be further ahead to consider other options. (ie non computer model, portable ect)
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Old 08-06-2015, 10:47 AM   #9
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One more thing to investigate. Dinosaur Electronics makes some replacement boards for Cummins/Onan generators. The part number you gave is not on their list, but I'm wondering if you opened up the inverter assembly, if there is board inside that is replaceable, but not available from Cummins. Like the AC compressor on my Jeep, the clutch went bad, but Jeep doesn't sell the clutch without buying the compressor....


I think it would be worth a call to the folks at Dinosaur Electronics to see if they happen to have the board. (541) 994-4344 I'm sure they can easily tell you if they can help you.

Just something to consider. Those boards are all around $200 or less.
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Old 08-06-2015, 10:47 AM   #10
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I would open it up and take a visual look before replacing the board. Maybe a bad connection?
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