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Onan 7.5 HDKAJ Code 3-13


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  #1  
Old 09-01-2017, 03:51:20 PM
155mm 155mm is offline
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Default Onan 7.5 HDKAJ Code 3-13

I have read thru, I hope, all of the HDKAJ posts and didnt see my error, so if there is a thread please point me in that direction.

Have a new to me camper,
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and it had this genny in it, with about 430 hours on the meter, HDKAJ ... C
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The problem I am having, it runs just fine until the outside temp is above 85*F, then it shuts down. Flashes 3-13.... 13 is undervoltage. The genny will do this code even when the breaker is shut off and the engine is cold. When the jenny runs, there is no issues pulling both AC units and the microwave all at the same time.

I dont know if the outside temp has anything to do with the shut down code, just giving all the info that I have.

The genny is buried in the front of the camper, so I have to plan on disassembling the front of the camp to work on it.

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It had a full service done (air filter, oil filter, oil, fuel filter, water pump belt, coolant tested) about 30 hours, 3 months ago.
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  #2  
Old 09-01-2017, 03:59:23 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Your gen is spec C, made July of 1996
Looking at schematic on pfd page 92 of service manual looks like this gen is an INVERTER type.

I see that it has a water temp sensor, could check that connections to it are clean.


Link to manuals on it.
http://www.twinslan.net/~n0nas/manuals/onan/

When in link press control-F bring up search mode. type in hdkaj and search on it

Should bring up several manuals, service, parts , install, operator.

Read the service manual. Error codes as usually at rear of manual.
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Old 09-01-2017, 05:26:53 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Could be something simple like a loose belt, there is no belt tensioning as such just 2 pulleys. I would also be checking that the rad is clean and there is no debris buildup impeding airflow. If you get the unit out it is fairly easy to get the panels off to access the internals. I have a HDKAT that I resurrected from the dead with a 1$ MOV. The question is , is the code the cause or the effect, ie is it shutting down because of under voltage or is it observing undervoltage as it shuts down from some non specified/monitored condition. I had this issue on another computer controlled Onan gen. Cheers Dan
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Old 09-01-2017, 07:27:25 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

It is acting the same, before and after the belt change, the rad was clean enough to see thru.
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Old 09-11-2017, 10:28:47 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Does anyone have a link for a hdkaj service manual that works? I have a intermittent code 11...over current.

timAZ
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Old 09-11-2017, 10:39:16 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Link has been down for a few days, server issues.

Read this , another link to manuals is near end.
https://www.smokstak.com/forum/showt...=155507&page=2
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Old 09-11-2017, 11:27:24 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

thank you, but the only thing that comes up when I search for hdkaj is a spec sheet.

TimAZ
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Old 09-12-2017, 05:50:08 AM
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Default Re: Onan 7.5 HDKAJ Code 3-13

The server issue is taking longer than we expect, and the temporary Google drive page is missing many of the files. I can send you the manuals by email if you wish, just PM me an email address that can accept large attachments.

981-0161 Operator
981-0200 parts
981-0514 engine service
981-0522 Generator service
981-0623 install
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Old 09-12-2017, 07:12:21 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Thanks again for your help Kevin!
Is there anyone on here with information to pin-out the inverter-controller. The manual only states to replace it. I'm that is very pricey.

Thank you for your help,

TimAZ

Thanks again for your help Kevin!
Is there anyone on here with information to pin-out the inverter-controller. The manual only states to replace it. I'm guessing that is very pricey.

Thank you for your help,

TimAZ
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Old 09-12-2017, 11:50:22 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

I got one with a failed inverter/controller turned out to be a $1 MOV had failed. I would definitley take the inverter out and give the circuit board a visual check for cold solder joints , bulging capacitors or burnt components. If you have a buddy who is good with electronics it would be a good idea to have him have a look at it for you. They are actually fairly well made and the components are not too hard to get at just a million screws to get it out. Cheers Dan
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Old 09-13-2017, 08:22:00 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Thank you Dan
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Old 09-17-2017, 10:47:28 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

You were right Dan...a million screws. I have it out now. I know this sounds silly, but I can't get it open...I have all of the screws out of the part with the heat sink. It will now come apart. What am I missing???

Tim
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Old 09-18-2017, 12:00:08 AM
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Default Re: Onan 7.5 HDKAJ Code 3-13

You have to remove the inverter from the generator case , it has some screws which come in from the radiator side of the sheetmetal. There are also some which hold the lower case to the chassis of the gen, they are down low in the air intake area. There is a matching set on the front of the case facing the front (access panel side) Only other thing I can think of is that you have to remove the screws that hold the two multi pin plugs on the upper edge of the inverter. The inverter housing splits vertically . but the cases come apart from the top not the heatsink side. It has been a few months but I seem to recall lots and lots of screws. Cheers Dan
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Old 09-18-2017, 11:22:21 AM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Yep, I have it out and am trying to split it that way. So is the control board in the side that has the heat sink or the other side? I will try to split it again tonight.
Thanks again.

Tim
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Old 09-18-2017, 11:41:47 PM
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Red face Re: Onan 7.5 HDKAJ Code 3-13

OKay I feel dumb. I have it apart. no smoking gun. Does anyone have a wiring diagram for the control board? Please

Tim

Sorry this is for code 3-11...over current.

Tim

Does anyone have a wiring diagram for this board part number
5-00800-5216
ESI 9948

Tim
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Old 09-19-2017, 12:29:05 AM
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Default Re: Onan 7.5 HDKAJ Code 3-13

I don't have a wiring diagram but someone might. I started by looking for burnt components or physical damage or corrosion and found something right away , a red flat capacitor looking thing which turned out to be a MOV had shorted across the power supply input. Turns out that was the only thing wrong with my board. The next thing on my path was to look for bulging electrolytic capacitors and replace them. Then taking a magnifying glass and looking for cold solder joints and reflowing them. Very tedious as there are many many joints. You can test the rectifiers and there is a thread on testing the IGBTs but I don't think that is your problem. You are looking for some sort of anomaly but it is hard to say where it might be. I'm not even that good with electronics but i can see when something doesn't look right. After you have done a few of these things put a few screws back in and reinstall to see if it is working. Cheers Dan
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Old 09-19-2017, 07:10:04 AM
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Default Re: Onan 7.5 HDKAJ Code 3-13

As far as I know, Onan never released a wiring diagram of the module. I certainly don't have one. If anyone does, please post it, it would be a welcome addition to our collection.

A couple of suggestions. Please bear in mind that I do not have any experience with this generator, and have never even seen one.

Did you try calling Flight Systems to see if they repair this board?.

If you have access to an ESR meter, it can test capacitors in circuit, with the power off. This has helped me troubleshoot all kind of strange and intermittent problems.

If you can make an extender harness, you can test the board under operating conditions.
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Old 09-19-2017, 09:00:17 AM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Thank you Kevin,

Flight Systems doesn't touch this one.
they say it has propitiatory parts...
Thank you guys for your help.

Tim
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Old 09-19-2017, 10:24:08 AM
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Default Re: Onan 7.5 HDKAJ Code 3-13

I'm sure it does have propitiatory parts, namely the microcontroller which is apparently operating because it starts and runs, then shuts down with a under voltage code. The problem may be as simple as a loose pin in one of the connectors that send the sample voltage back to the board. If it were mine I would keep trying.
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Old 09-19-2017, 12:02:06 PM
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Default Re: Onan 7.5 HDKAJ Code 3-13

Grasping at straws here, but: check electrolytic caps for bulging/domed tops, they should be flat. These are the ones in aluminum cans.

Was there any debris clogging any air vents or over the heat sink when you took it apart?
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