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Onan 7.5 HDKAJ Code 3-13


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  #11  
Old 09-13-2017, 08:22:00 PM
timaz timaz is offline
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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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