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bobsallyh

Livingston, TX.

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Posted: 07/24/18 08:01am Link  |  Quote  |  Print  |  Notify Moderator

I just wish Kubota, Yamaha, or Honda would make direct replacements for Onan RV gennys. Onans are like an old woman, needs a lot of TLC!

maillemaker

office

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Posted: 07/24/18 08:33am Link  |  Quote  |  Print  |  Notify Moderator

The place to go for Onan trouble shooting is here:

https://www.smokstak.com/forum/forumdisplay.php?f=1

They also have factory service manuals for your models, which include diagnostic procedures.

I'm in the middle of fighting with my Onan and have been for months. This week I'm pulling the voltage regulator and control board (both Flight Systems replacements replaced in 2009) and sending them in for testing ($35 each which they refund if you buy a new board).

Steve


1990 Winnebago Warrior. "She may not look like much but she's got it where it counts!"



Straylight

The Road

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Posted: 07/24/18 11:07am Link  |  Quote  |  Print  |  Notify Moderator

Here's some stuff you can do in half an hour with absolutely no training. They have nothing to do with the fault code; they are general tests for a novice. They will cost very little money and time.
  • Fill the tank with more gas. Consider adding whatever fuel additive you find at the gas station: Seafoam, Stabil, Techron. Follow the directions on the bottle that you get. I'm recommending an additive because it can almost never hurt and it sounds like your generator might need some TLC, and a basic fuel additive is a very easy and simple way to provide a small amount of help.
  • Check the air filter by taking to cover off the generator, locating the boxy metal housing in the top left, unscrewing the wingnut on the far left of that housing, removing the metal cover, and pulling out the air filter. It should look cleanish and whitish.
  • Check the oil by removing the yellow oil cap in the bottom right of the generator. The oil should be between the correct lines on the dipstick (which is attached to the cap itself). If you want to change the oil, it's almost identical to doing so in a car, except you remove a small plate on the underside of the generator (two Torx screws) and then remove the large hex bolt revealed by the removal of the plate. This will drain the oil.
  • Check the governor linkage (to the throttle) and the choke linkage (to the choke). These are the two long bars attached to spring-loaded clip looking things on top of the carburetor (which is the complicated silver thing directly in the center, to the right of the air filter housing and to the upper left of the oil cap). When you grasp and move these linkages back and forth, they should move freely and smoothly, returning easily to their original position.


If none of these quick interventions show something obviously amiss (low fuel, bad filter, low or bad oil, stuck linkages), you will either need to learn how to troubleshoot more complicated problems yourself OR take it to your local Cummins Onan shop.

Cummins service comes at a premium. Expect two hours of labor at $140/hr just to diagnose your problem. However, the technicians should be honest, communicative, and helpful, as is the Cummins reputation.

An intelligent and wrench-experienced person should be able to replace a fuel pump, fuel filter, carburetor, control board, voltage regulator, air filter, throttle or choke linkage, fuel line, carburetor gasket, governor spring or linkage spring, or starting solenoid on his or her own without much trouble. (Not saying all those things could be the problem, but that's a good start for things you can fix on the ground in front of your generator.) Many other things require you to "drop" the generator off the motorhome; you would need a transmission jack or similar floor jack and a whole bunch of PB Blaster and wrenching on the retaining bolts. Most people have Cummins perform that kind of work, because it is an Enormous Pain in the Butt.

Your generator is a 4KY Spec K. Parts, service, and operator manuals can all be found on the internet or bought for $15-20 online. I just fixed a 4KY Spec H and would be happy to help you out. Do everything listed here and report back.

Straylight

The Road

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Posted: 07/24/18 11:23am Link  |  Quote  |  Print  |  Notify Moderator

Also, it's my understanding that the Slip Stick will not work on 4KY models, because the slip rings are not visible to the eye behind an accessible vent. I could be wrong.

road-runner

Oregon

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Posted: 07/24/18 12:46pm Link  |  Quote  |  Print  |  Notify Moderator

bobsallyh wrote:

I just wish Kubota, Yamaha, or Honda would make direct replacements for Onan RV gennys. Onans are like an old woman, needs a lot of TLC!
I second that! Up to about 10 years or so ago Honda offered the 4,000 VA EV4010 and 6,000 VA EV6010 RV generators that I vaguely remember fit into the same physical space as the Onans. They were still 3,600 rpm constant speed devices, but were twin cylinder and liquid cooled, which I expect would lead to smoother and quieter operation. I guess there's just not enough volume in RV generators for more than one vendor. I think Generac is out of the market, too. In addition to microquiet clones, they had a couple of variable speed inverter models that looked pretty good in terms of specs and features, but had reliability and support issues (based on what I've read). I think an rv-repackaged eu3000i would be pretty darn popular.


2009 Fleetwood Icon

g92065

San Diego

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Posted: 08/12/18 10:46pm Link  |  Quote  |  Print  |  Notify Moderator

road-runner wrote:

bobsallyh wrote:

I just wish Kubota, Yamaha, or Honda would make direct replacements for Onan RV gennys. Onans are like an old woman, needs a lot of TLC!
I second that! Up to about 10 years or so ago Honda offered the 4,000 VA EV4010 and 6,000 VA EV6010 RV generators that I vaguely remember fit into the same physical space as the Onans. They were still 3,600 rpm constant speed devices, but were twin cylinder and liquid cooled, which I expect would lead to smoother and quieter operation. I guess there's just not enough volume in RV generators for more than one vendor. I think Generac is out of the market, too. In addition to microquiet clones, they had a couple of variable speed inverter models that looked pretty good in terms of specs and features, but had reliability and support issues (based on what I've read). I think an rv-repackaged eu3000i would be pretty darn popular.

I'm going to THIRD this! Our 99 Xplorer has a 2.8 Onan, it always cranks, but sometimes it doesn't start. Sometimes, it does. Once it started, but would not generate power. Sometimes, it runs smooth, sometimes it surges. I'm tired of the inconsistency and noise. Why hasn't someone used the new inverter technology from the portables for a built-in on-board genny?

Gerard

gmctoyman

Lake Livingston, Texas

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Posted: 08/17/18 08:59am Link  |  Quote  |  Print  |  Notify Moderator

We can only hope for an Onan replacement....SOON ! I had a liquid cooled Honda in my GMC motorhome, it seemed to be a much less irritating sound than the Onan...and it was dependable. Shoulda kept it, the generator was worth more than the MH.


Dave W. AKA "Toyman"
KE5GOH - On 146.52
RV's ? What RV's ???
Apache Pop-up
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Do Boats Count ?

gmctoyman

Lake Livingston, Texas

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Posted: 10/31/18 04:37pm Link  |  Quote  |  Print  |  Notify Moderator

Wonder how tall a Champion 3400 would be if you took the handles & Fuel tank off the top? Not concerned about warranty issues, nor closing the top of the case. Just looking for a inverter type replacement that will fit.

185EZ

Infinity and Beyond

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Posted: 10/31/18 05:41pm Link  |  Quote  |  Print  |  Notify Moderator

somebody needs to burn this thread
never found out the initial problem and now we're talking about a portable generator

MEXICOWANDERER

las peƱas, michoacan, mexico

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Posted: 10/31/18 05:50pm Link  |  Quote  |  Print  |  Notify Moderator

It is inevitable when the following are coupled

Minimal mechanical diagnostic aptitude
No diagnostic tools

Failure to remain in contact with the forum
Failure of forum members to utilize self-control and help the OP focus and stay focused.

The OP will become overwhelmed and submerge.

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