Onan 4000 Watt Generator, Not Making Power Part 1
ฝัง
- เผยแพร่เมื่อ 24 ส.ค. 2021
- This generator was brought to me. By the description the customer gave me, I am assuming that it is not making power. I access the brushes to inspect them and WOW !!!!!! Watch to see what I found.
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Ive got a 5000 watt onan but its currently making 1.5 volt. Its runs with no other issue other then the output
im currently questioning the voltage regulator but currently learning from TH-cam videos😅
By far, the best video of how to fix onan gen, you're the man thanks!!!
You're welcome!
Great video.
I spent 2 days working on my 4000 microlite, replaced fuel pump and installed new pump outside the compartment to have quick access as soon as the new pump fails again. Removed carburetor and cleaned I very well.
I was so happy to get it running again without mechanical skills. This happiness lasted 1 day because today stopped working. Went to check why and smoke and burnt plastic smell coming from the rotor fan. The new fuel line was a bit large and rubbed against the fan almost getting destroyed creating a hazard fire.
Now it only runs if I keep pressing the switch.
Man if I need to do what I’m seeing probably I’ll need to throw the generator to the dump and get a second hand.
I am sorry that you had so much trouble.
Good video. I think your one of those guys that could repair anything but a broken heart and the crack of dawn.
Well, Melvin. Some things can't be fixed...
Ok
That was great! Sent a note to my brother about Mrs. Hill Billy’s puzzle from the last video I watched. Very entertaining as well as informative.
Awesome, glad you enjoyed them.
I love the way you tell it true thanks for the honest videos have a great day look forward to part two
Me too...waiting on parts
Just wanted to say great video and thank you for answering many of your viewers questions. That always means a bunch to is
You are welcome.
Awesome man thank you for sharing...
You are welcome
A lot of work. Waiting for the 2nd episode. Thanks Don
Waiting on parts
@@hillbillyrv ofcourse. Its amazing how we depend upon other countries.
@@daviscrt yes it is
THIS IS HOW I FIXED MINE, IN THE CASE OF....
"I CAN'T START MY GENERATOR"
It's has been two years since last time it was running, so I started by checking oil level full at gen dipstick (it won't start if low oil because of sensors) then I checked gasoline more than 1\4 tank in the RV (also safety sensors), sparkplug checked for good spark, also checked the manual reset circuit braker ( to be ON) at front motorhome engine compartment for 12v current to the generator to be able to start it, also cleaned the carburetor and even installed new one but same situation, then checked wires and found some has been chewed like gum by rats at the back of starting switch generator panel so I replaced them, at this time the generator started but stay running only by keep pushing the switch on all the time, so then finally I knew it was internal electrical problem from the engine itself, so I took the generator out from my RV to work in my garage, (I did this by myself with some tools and old Mayan tricks ) lol, it's really heavy for one person.
I disassemble the unit at my garage and started by removing the cover, then the cooling fan or flywheel unit (it's 2 items in one) until finally I was at the gen rotor and brushes assembly area and this is what I found: one more wire chewed by filthy rats plus the stinky rat nest in the middle of the generator motor coil, I fixed the wire and sanded the commutator copper contacts where the brushes are sitting becouse they were real duty with old urine from the rats, and of course I got rid off the stinky nest, lol!!!
Then I assembled everything back together and... bingo it's runing like a champion!!!
For this project materials involved was about $60.00 including an aftermarket new carburetor and an harmonic balancer/steering wheel puller (available at any auto parts for $25.00) to pull the aluminum fan out and (flywheel).
Just picture this: (Any gasoline engine run smooth if gasoline and DC current aren't interrupted) so following this important principle you'll always find the problem to be fixed.
Also if you have a onan microlite 4000 like mine, don't run it for more than a minute without the cover because you'll cook the engine real fast, also keep the eye on the aluminium fan and your fingers after cranking it in case you missing one or two members...just kidding, lol!!!
After testing the gen with the help of a gasoline container, a piece of hose and 12v battery, I did put the air cooling assembly back and the rest of components including the cover, then it was ready to be installed at my RV.
Once the gen was installed back at my motorhome I started it to be tested for 120v electricity but not before flipping the AC circuit switch (on) at the gen starting control panel (sometimes hiding under or around the panel) to be able to transfer power to my RV GFCI main outlet and electric panel as well, my motorhome it's equipped with GFCI so I reset it and tested for green led light indicating power is ready at my main breakers panel, so I turned my main breaker (on) along the others ones but no power was present at my breaker main switch (faulty main braker) so I flipped it many times, sometimes you can make it work again, mine did work, lol!!!
I'm happy because everything works now including the refrigerator for cold drinks and AC for this crazy summer, lol! Later I'll buy me a new main braker, for now this is a resurrected generator story that needed to be shared.
If this can help eaven one person to save time and $$$ it'll make me more happy, thanks for reading.
Very good. Glad you got it going.
Muy excelente trabajo
I ALWAYS make sure my repair men have overalls... they are the best!
Fat boys look funny in overalls. ha ha
Great video.
Yep yep to clean up the slip rings with the Scotch-Brite pad.
Then they look good as new.
That should work.
He's down to earth looks like stuff that would happen to me
Ha ha. We all have our struggles.
Boy, I’ve changed oil a bunch on four of those we used at fiber optic regen sites along the pipeline. We had two in a small building mounted in a closet mounted on drawers. These things ran most of the day to charge batteries.
Did you have trick for getting the oil back in them? That last half a quart takes forever, if you are trying not to make mess.
@@hillbillyrv I had that problem a few times so I so I would make the oil hot sitting on the floor of my truck under the heater. We used these for two years and all four had thousands of hours on them then the company bought a 16Kw Propane Onan in an insulated enclosure.
@@Chris_at_Home That's cool. We almost never see many hours on RV generators. I don't know what happened to the brush in this one. It only has about 700 hours on it.
@@hillbillyrv The bigger generator was bought because the small ones were worn out. Propane isn’t good long term on the cylinder walls. The pipeline won’t let us use diesel on the ROW.
Thanks
You are welcome
Thanks 😊
You are welcome.
Love the video...great info. I have a question, my Onan 4000 it runs great but only puts out about 30V AC....my instinct tells me its the regulator what are your thoughts?
That can be so many things. One of which is the voltage regulator.
I got that cover off mine without unbolting it from the pan.
4KY P
Awesome
18:30 - I don't think my flywheel was threaded. I took a small punch and hit the key stock and the wheel just slipped off.
If all else fails, hit it with a hammer.
2021 onan 4000 generator ran last week now no solenoid click, no fault light on switch at generator silence. what do you think?
Battery voltage not getting to the generator or solenoid bad or no signal from switch to solenoid.
Could you show how to install auto gen start directly to the gen
I have no idea how to do that.
Forgot one thing...Flight System sells a 'Slick stick' for cleaning the slip rings.
Uh. I didn't know they made something especially for that job. I have just always used erasers.
So a little verbose on the words. Showing the pin outs for the plugs would have been nice. Showing the wiring diagram would have been divine. Showing how to ohm out the brush block would have been made it a "super tech" video.
Ok
Thanx for keeping it💯🇺🇸🇲🇽
You are welcome
I am dealing with the exact same things and cannot get an answer as to which side of the brush block to plug the reattached F+ & F- to. The online wiring diagram only calls them F1 & F2. I also found the following in the service manual: "Connect the F2 lead wire to the outer brush terminal (near bearing) and the F1 lead wire to the inner brush terminal." This does not help me since my wires are F+ & F-. I wish someone could help me translate them. I watched a video from Flight Systems and he was working on a Marquis/Emerald generator and specifically said that the polarity mattered. I just don't know if that is the same with the 4000 micro quiet.
Sorry, I can't answer that.
My 6300 watts horse power are and if you got the manual servicio
My MEP003A is locked up, I bought it and it has been sitting outside with open exhaust. What's the best way to add oil to cylinders,too see if I can free it up. I have never worked on diesel engines. Where can I get manuals?
I don't know what an MEP003A is.
I've got a microlite 4000 spec B, trying to get the end bell off to remove the rotor seems the bearing is frozen where bell meets rotor shaft. Any way I can unfreeze/loosen this without causing damage to the bearing/rotor shaft?
That bearing is just a friction fit. It is not pressed in. It should come out pretty easy.
@@hillbillyrv oh ok, it just seems to not want to budge as it is hung up there (the end bell), also I'm removing the rotor because it's showing high resistance at slip rings
how many hours was on the generator, and any idea why one brush was that much more worn. thanks as always.
I believe 700 hours and I have no idea why they wore that way.
Hello. So I have a 90s Kohler 4500 ckm 21. I couldn’t get it to start with the start/stop switch. I removed it and left the wires disconnected and wired in a key switch. It starts fine now but no power. What did I do wrong
Does it need power to excite the generator??
There is an exciter circuit.
I had the same problem would run 10 minutes to an hour. Ended up being the fuel pump. Most have auto shut off if they're low on oil also. Onan wanted 300.00 for fuel pump so I put a 12 volt electric fuel pump and rerouted line for under 25.00
You don't have to use Onan fuel pump, but it still needs to be a very low pressure pump. Automotive pumps usually have too much pressure.
@@hillbillyrv it worked great for the last 3 years I owned it, so maybe it was a low pressure pump, not sure. It was only about 2"X2"
@@johnbernhard5096 If it works, it is probably a low pressure.
Yep same problem I had with mine one of the wires going to one of the brushes there was too short.
I made a video about mine also.
Can I have the same problem when I let go of the button the motor would die
Yep
Hello my friend I got a Jenni Rider Just like that What is a Six Thousand 32 watts I want to know how much horsepower Something About That things
I don't understand.
I have an onan 4000 that fires right up but will only stay running if i hold the start switch down. It will run that way and throws a code 4 for overcrank and that is the only code. Any suggestions? Power is lost to the carb and i have swapped the control module with a known good one.
Onan generators that are not making AC power will only run while you hold the start button down.
@@hillbillyrv i just checked and it is producing 110vac when running
back watching your video second time
have you any experience with one of these starting with low-power say round 80 v over the let it run for around 10 minutes and it slowly builds up to normal 123
have you ever heard of this could have something to do with the brushes
appreciate any thoughts 🦧
✌️
That sounds like a short in the rotor or stator that makes better connection after it heats up.
@@hillbillyrv 🦧
do you have experience with older model 4000 BGE.,. and what can you tell me about the stator or if there is more than 0NE
somehow I have always thought of a short as something that you don't want to make a better connection❓
@@TOTMGreenish-Top-Of-The-Morrin It is really tough testing a rotor or stator.
Hey Hillbilly! I have a Onan Marquis 7000 in a 1997 Holiday Rambler. I changed the oil & filter, replaced spark plugs, replaced air filter, replaced fuel filter, replaced fuel pump, replaced fuel line, and checked all fuses. It now runs great, purrs like a kitten. However, it doesn't rev up when a load is applied. It will run fine under a small load but if I turn on one of air conditioners and another thing or two, it will bog down and shut off. It always starts right back up but when I repeat the process it has the same results. What would you check now?
Sounds like the governor is not working correctly or not adjusted correctly. It should never rev up. It has to run the same speed all the time in order to keep the correct Hz of 60 plus or minus 2 Hz.
@@hillbillyrv Is there a manual or other instructions on how to test and/or set the governor?
@@4JsPlantation Yes. Contact an authorized Onan dealer. They should be able to help you out.
@@hillbillyrv Tried that, no good. It's from a 1997 and they claim to no longer carry records or info from that far back.
@@4JsPlantation They didn't throw the books away, they are just too lazy to go look for it. Everybody was still using books up until 10 years ago. Now everything is digital.
The holes you use for the puller aren't tapped. you're going to have to tap them first and then use a puller to get the flywheel off
Ok. Thanks
Hi I have a a 1991 onan emerald plus gen set. It runs fine and powers the rv for 5minutes. Then surges, the house power goes out, it stays running but makes a loud clanking sound like there are loose
screws jumping around inside of it. When it calms down (idling) the house power comes back on.
Needs an exorcist? ha ha I don't think I ever heard of that one before.
I don't have an exorcist. Hoping someone has had the same problem. Any ideas?
@@susieingle3695 Go to Hillbilly RV FaceBook page and post it there, maybe someone will have answers for you.
I think you're supposed to tap those holes at like 8 mm if my memory serves me correctly..
Ok
You need an impact to get that bolt out of the flywheel
I think I got it.
What is the part number for the muffler on the Onan 4000?
You will have to contact your local Onan dealer to get that info.
It’s the muffler
@@tracyscott3659 I don't have access to Onan part numbers. You will have to call your local Onan dealer.
Hi
My onan generator start ok
And power ok
But no cranks
Can you help me
Thank you so much
When we say crank, that means the starter turns the engine. You sat it runs and makes power, but no crank. I don't understand.
Can I contact you about a generator issue I am having? Thanks
Ask your question here. Generators are hard enough to fix when I can put my hands on them. Really hard to diagnose over great distances.
My onan 4000 watt generator the muffle it's running to hot.
A gasoline engine will produce exhaust temps over 1000 degrees normally. How hot is yours?
It's berry berry hot like red .
It more than 1000 degrees berry red.
@@luisadorno3254 I have never heard of that.
I see another guy who has the same problem in your tube. But no explanation what caused the problem. any idea.
high presser air in holes full of filings without eye protection ? silly boy
Don't tell OSHA
What a pain in the A I think I’ll keep my portable generator 🤬
I used to love working on generators, but I have fallen out of love with them.
@@hillbillyrv yes I think you mentioned that at the start of your video looking forward to part 2
@@coreymerritt7742 Parts ordered...now we wait
I'm guessing you don't like working on generator's any more because...hmmm, I'm gonna take a guess...wait for it...
they're a pain in the arse??!!!
Actually generators were my favorite things to work on but parts for them have been difficult to get even way before Covid. Onan parts are incredibly expensive too and Generac RV has been obsolete for a long time.
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