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I have a Onan 4000 GenSet problem.

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Albert

unread,
Oct 7, 2012, 12:45:07 PM10/7/12
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I have a Onan Microlite™ 4000 Series that I've had a problem with.
When I first bought my 2003 Holiday Rambler I chose not to have it
generator prepped because I got to figuring if I put a generator
onboard I would lose quite a bit of storage space. So I decided to go
another direction when I bought the generator. Which is shown below (
http://www.lasonwebpage.com/Camping_Stuff.html ). As an added feature
of this configuration I can use the generator for auxiliary power
anywhere I can take to pick up by rigging up a battery hookup
receptacle on the pickup.

Every six months I start and run it for about an hour and then put it
back in storage. About a week ago I pulled it out and it wouldn't run.
I was getting a fault that indicated I should check my fuel level in
the tank (in other words out of fuel). I knew I had fuel and the
generator would start but only run about 30 seconds and then I would
get a shutdown fault indicating I wasn't getting any fuel.

So I pulled the fuel line off the carburetor and hit the primer
pre-start on the switch and had plenty of fuel. I change the spark
plug and fuel pump that didn't help. Out of frustration I took it down
to Cummins to have it checked out and they had to put a new carburetor
on it and they told me that the carburetor was varnished up. I brought
back the old carburetor and sure enough it was.

Now, it was explained to me that when I winterized the generator that
I should have run all of the fuel out of the carburetor which
unfortunately I did not so from now on I will disconnect the fuel line
from now on and do just that.

Because I'm using an outboard motor fuel tank it's easy for me to
disconnect the fuel. But if this generator were mounted say in a
motorhome it would probably have to have a fuel tank shut-off valve,
I'm just guessing. The generator itself does not have one.

Anyway, I just thought I would pass this along so maybe someone else
will not make the same mistake I did to the tune of $455 :-(. On the
bright side I did clean the varnish from the old carburetor so I now
have a spare carburetor and fuel pump.

Albert

Tom J

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Oct 7, 2012, 1:42:47 PM10/7/12
to
Albert wrote:
> I have a Onan MicroliteT 4000 Series that I've had a problem with.
> When I first bought my 2003 Holiday Rambler I chose not to have it
> generator prepped because I got to figuring if I put a generator
> onboard I would lose quite a bit of storage space. So I decided to go
> another direction when I bought the generator. Which is shown below (
> http://www.lasonwebpage.com/Camping_Stuff.html ). As an added feature
> of this configuration I can use the generator for auxiliary power
> anywhere I can take to pick up by rigging up a battery hookup
> receptacle on the pickup.
>
> Every six months I start and run it for about an hour and then put it
> back in storage.

It's my opinion that is what caused the problem started. The generator
should be run under load for a couple of hours every month to keep it
working properly, not only the fuel system but the electrical parts that
retain moisture if not warmed up regularly. I have a portable 4K generator
that is 10 years old that has never failed to start because it is run under
load every month when I'm home, or as soon as I get home. When I bought my
current used motorhome that had not been used for a few months it had the
same problem you describe EXCEPT the Onan mechanic cleaned to carburetor and
put it back on!!

Tom J


Neon John

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Oct 7, 2012, 3:39:22 PM10/7/12
to
On Sun, 07 Oct 2012 10:45:07 -0600, Albert <aml...@hotmail.com>
wrote:

>
>Now, it was explained to me that when I winterized the generator that
>I should have run all of the fuel out of the carburetor which
>unfortunately I did not so from now on I will disconnect the fuel line
>from now on and do just that.

That is the single most important thing you can do to ensure long
lives and easy starting.

For example, last week I had to get out my Cordless Battery Charger

http://www.neon-john.com/Generator/CBC/CBC_home.htm

to charge the batteries on my big diesel truck and do it fast. I
hadn't run the CDC in probably 5 years. New fuel, open the valve and
crank on the first pull! That's the way I like it. :-)
>
>Because I'm using an outboard motor fuel tank it's easy for me to
>disconnect the fuel. But if this generator were mounted say in a
>motorhome it would probably have to have a fuel tank shut-off valve,
>I'm just guessing. The generator itself does not have one.

My MH didn't have a fuel cut-off so that was the first thing I
installed. Something everyone who doesn't use their generator much
should do.

>
>Anyway, I just thought I would pass this along so maybe someone else
>will not make the same mistake I did to the tune of $455 :-(. On the
>bright side I did clean the varnish from the old carburetor so I now
>have a spare carburetor and fuel pump.

OUCH! That hurts.

John
John DeArmond
http://www.neon-john.com
http://www.fluxeon.com
Tellico Plains, Occupied TN
See website for email address

Albert

unread,
Oct 7, 2012, 5:24:50 PM10/7/12
to
On Sun, 7 Oct 2012 13:42:47 -0400, "Tom J" <tomn...@earthlink.net>
wrote:
Not to belabor the point but as it was explained to me when you shut
the generator down and leave the fuel in the carburetor to evaporate
the longer the down time the more evaporation leaving more varnish.
This has been my routine now for the last six years because I don't
use the generator at campouts because our Good Sam's chapter stays at
full hookup campgrounds.

The mechanic also explained that if you intend to put your RV/
generator in winter storage you winterize the generator by running the
carburetor dry not giving it a chance to evaporate and leave varnish
residue. He also said any running of the generator over twice a year
to maintain lubrication is a waste and unneeded wear and tear on the
engine and generator.

I know they got to me on the cost and I will chalk it up to experience
that particular shop won't have a chance at me again.
Albert

Albert

unread,
Oct 7, 2012, 5:30:38 PM10/7/12
to
On Sun, 07 Oct 2012 15:39:22 -0400, Neon John <n...@never.com> wrote:

>On Sun, 07 Oct 2012 10:45:07 -0600, Albert <aml...@hotmail.com>
>wrote:
>
>>
>>Now, it was explained to me that when I winterized the generator that
>>I should have run all of the fuel out of the carburetor which
>>unfortunately I did not so from now on I will disconnect the fuel line
>>from now on and do just that.
>
>That is the single most important thing you can do to ensure long
>lives and easy starting.
>
>For example, last week I had to get out my Cordless Battery Charger
>
>http://www.neon-john.com/Generator/CBC/CBC_home.htm

John, why don't you put wheels on that sucker :-)? You could put
wheels on it like a dolly.

>to charge the batteries on my big diesel truck and do it fast. I
>hadn't run the CDC in probably 5 years. New fuel, open the valve and
>crank on the first pull! That's the way I like it. :-)
>>
>>Because I'm using an outboard motor fuel tank it's easy for me to
>>disconnect the fuel. But if this generator were mounted say in a
>>motorhome it would probably have to have a fuel tank shut-off valve,
>>I'm just guessing. The generator itself does not have one.
>
>My MH didn't have a fuel cut-off so that was the first thing I
>installed. Something everyone who doesn't use their generator much
>should do.
>
>>
>>Anyway, I just thought I would pass this along so maybe someone else
>>will not make the same mistake I did to the tune of $455 :-(. On the
>>bright side I did clean the varnish from the old carburetor so I now
>>have a spare carburetor and fuel pump.
>
>OUCH! That hurts.

Like I said to Tom J that shop won't be getting to me anymore.

>John
>John DeArmond
>http://www.neon-john.com
>http://www.fluxeon.com
>Tellico Plains, Occupied TN
>See website for email address
Albert Lason
27'Holiday Rambler Alumascape (2003)
1992 Dodge 3/4 ton Cummins diesel
4000 Onan generator
"s" instead of "z" to e-mail me

Bob Hatch

unread,
Oct 7, 2012, 5:44:13 PM10/7/12
to
On 10/7/2012 9:45 AM, Albert wrote:
> I have a Onan Microlite™ 4000 Series that I've had a problem with.
> When I first bought my 2003 Holiday Rambler I chose not to have it
> generator prepped because I got to figuring if I put a generator
> onboard I would lose quite a bit of storage space. So I decided to go
> another direction when I bought the generator. Which is shown below (
> http://www.lasonwebpage.com/Camping_Stuff.html ). As an added feature
> of this configuration I can use the generator for auxiliary power
> anywhere I can take to pick up by rigging up a battery hookup
> receptacle on the pickup.
>
> Every six months I start and run it for about an hour and then put it
> back in storage.

I don't think that's what Onan says to do. What does your manual say?
Mine says 2 hours per month under 1/2 load.


About a week ago I pulled it out and it wouldn't run.
> I was getting a fault that indicated I should check my fuel level in
> the tank (in other words out of fuel). I knew I had fuel and the
> generator would start but only run about 30 seconds and then I would
> get a shutdown fault indicating I wasn't getting any fuel.
>
> So I pulled the fuel line off the carburetor and hit the primer
> pre-start on the switch and had plenty of fuel. I change the spark
> plug and fuel pump that didn't help. Out of frustration I took it down
> to Cummins to have it checked out and they had to put a new carburetor
> on it and they told me that the carburetor was varnished up. I brought
> back the old carburetor and sure enough it was.
>
> Now, it was explained to me that when I winterized the generator that
> I should have run all of the fuel out of the carburetor which
> unfortunately I did not so from now on I will disconnect the fuel line
> from now on and do just that.
>
> Because I'm using an outboard motor fuel tank it's easy for me to
> disconnect the fuel. But if this generator were mounted say in a
> motorhome it would probably have to have a fuel tank shut-off valve,
> I'm just guessing. The generator itself does not have one.
>
> Anyway, I just thought I would pass this along so maybe someone else
> will not make the same mistake I did to the tune of $455 :-(. On the
> bright side I did clean the varnish from the old carburetor so I now
> have a spare carburetor and fuel pump.
>
> Albert
>


--
I do not carry a gun hoping that
I'll be able to shoot someone, anymore than
I carry a jack hoping I'll have a flat
tire.
Me.

Hank

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Oct 7, 2012, 6:51:17 PM10/7/12
to
On Sunday, October 7, 2012 5:24:56 PM UTC-4, Albert wrote:

>
>
>
> Not to belabor the point but as it was explained to me when you shut
>
> the generator down and leave the fuel in the carburetor to evaporate
>
> the longer the down time the more evaporation leaving more varnish.
>
> This has been my routine now for the last six years because I don't
>
> use the generator at campouts because our Good Sam's chapter stays at
>
> full hookup campgrounds.
>
>
>
> The mechanic also explained that if you intend to put your RV/
>
> generator in winter storage you winterize the generator by running the
>
> carburetor dry not giving it a chance to evaporate and leave varnish
>
> residue. He also said any running of the generator over twice a year
>
> to maintain lubrication is a waste and unneeded wear and tear on the
>
> engine and generator.
>
>
>
> I know they got to me on the cost and I will chalk it up to experience
>
> that particular shop won't have a chance at me again.
>
> Albert

I agree with running the gas out of the carb anytime you shut it down, even for only a week or two. However, I disagree with only running it twice a year, but that is only my opinion. I base this opinion on the possibility that if the engine can stop with the exhaust valve open. When it does, moisture could possibly enter, which could put a light rust on the cylinder walls. YMMV

I start mine up about every 30 days and run the A/C fan for a light load and to help keep rust and gunk from building up on the Fan motor shaft that is exposed to the weather.

About 6 years ago my A/C fan froze up and wouldn't turn (MH was 2 years old). I asked a dealer what caused it. He said they just go bad and wanted $110 for the motor. Being the cheapass that I am, I freed the motor up with very little effort. The next year after sitting all winter outside, it locked up again. I freed it up again. In the last few years I have been running the motor about every month or so with no problem. I store inside now. :-)

Hank

nothermark

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Oct 7, 2012, 7:11:35 PM10/7/12
to
On Sun, 07 Oct 2012 10:45:07 -0600, Albert <aml...@hotmail.com>
wrote:

Sounds like why I add the label amount of Stabil to the tank with the
last fill up for the season and then run the gen set for 20-30 min.

Albert

unread,
Oct 8, 2012, 12:13:18 AM10/8/12
to
On Sun, 07 Oct 2012 14:44:13 -0700, Bob Hatch <bob....@ymail.com>
wrote:
I'm quoting this from the Operator's Manual KY

EXERCISING THE GENERATOR

Exercise the GenSet at least two hours each month if used in
frequently. Run the GenSet at approximately 1/2 rated power. See
LOADING THE GENERATOR (Page 9). A single to our exercise. Is better
than several shorter periods.

Exercise the GenSet drives off moisture, re-lubricates the engine,
replaces stale fuel in the lines and carburetor and removes oxides
from electrical connections and generator slip rings. the Z result is
better starting, more reliable operation and longer engine life.


STORING THE GENSET
Proper storage is essential for preserving top GenSet
performance and reliability when the GenSet cannot be
exercise regularly and will be idle for more than 120 days

1. GASOLINE MODELS ONLY-fill the fuel tank with fresh fuel and add a
fuel preservative (Ona-Fresh�), follow the instructions on the
container label. Unless unless a preservative (stabilizer) is added,
the gasoline in the fuel system will deteriorate causing fuel system
corrosion, gum formation and garnish-like deposits which can lead to
hard starting and rough operations.

2. GASOLINE MODEL ONLY-Run GenSet for a bout 10 minutes at
approximately 1/2 rated power to fill the fuel lines and carburetor
with fresh fuel and preservative and to bring the GenSet up to
operating temperatures. See LOADING THE GENSET (Page 9). Then
disconnect all appliances, pushed the GenSet line circuit breaker to
off (Page 10) and stop the GenSet.

3. Remove the air filter and restart the GenSet. While the GenSet is
running, spray and engine fall dinner (OnaGard�) into the carburetor,
following the instructions on the container label, and then stopped
the GenSet. The fogger leaves a protective coat of oil on the internal
surfaces of the engine.

4. Changed the oil and attach a tag indicating oil viscosity. See
ENGINE OIL RECOMMENDATIONS (page 6).

Then he goes on to say in #5 how to disconnect the battery, #6
plugging the exhaust pipe and #7 "shut off the fuel supply valves (if
so equipped). #8 is about LPG models

You were correct about the exercising procedure but you must remember
that I am storing the GenSet not just letting it sit idle after
shutting it off. Now I will just take the extra precaution of running
the carburetor dry. Also I had not been using a stabilizer which I
bought from Cummins when I picked up the GenSet. I will also be using
the fuel for the lawnmower instead of leaving it in the gas tank. I
will continue taking it out of storage and starting it twice a year
probably until how I can figure out how to use it for emergency power
here at the house when we go off the grid? Or start camping again at
the federal campgrounds, decisions decisions decisions ;-)

Albert

Neon John

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Oct 9, 2012, 11:02:31 AM10/9/12
to
On Sun, 07 Oct 2012 15:30:38 -0600, Albert <aml...@hotmail.com>
wrote:


>>For example, last week I had to get out my Cordless Battery Charger
>>
>>http://www.neon-john.com/Generator/CBC/CBC_home.htm
>
>John, why don't you put wheels on that sucker :-)? You could put
>wheels on it like a dolly.

I built that thing when I was young and strapping and lifting 40 lbs
was nothing. Now that my back reminds of of my age daily, I put
wheels on it. In the form of the cheapest little hand truck HF sells.
The vertical pipes on the hand truck just happen to match up with the
width of the CBC's frame. 4 husky worm gear clamps to hold it in
place and I'm done.

>>>Anyway, I just thought I would pass this along so maybe someone else
>>>will not make the same mistake I did to the tune of $455 :-(. On the
>>>bright side I did clean the varnish from the old carburetor so I now
>>>have a spare carburetor and fuel pump.
>>
>>OUCH! That hurts.
>
>Like I said to Tom J that shop won't be getting to me anymore.

Actually, in Onan World, I'm surprised that you got out that cheap.
Many years ago they wanted almost $400 for a new carb for my AJ! It
was just a lawn mower carb, ferchristsake. The only thing wrong was
that the hole where the throttle shaft went in was worn, allowing air
in and fouling up the mixture. I ended up fixing the old one by
boring out the body and inserting a brass bushing.

Neon John

unread,
Oct 9, 2012, 11:05:57 AM10/9/12
to
On Sun, 07 Oct 2012 14:44:13 -0700, Bob Hatch <bob....@ymail.com>
wrote:


>> Every six months I start and run it for about an hour and then put it
>> back in storage.
>
>I don't think that's what Onan says to do. What does your manual say?
>Mine says 2 hours per month under 1/2 load.

Mfr's advice is all over the place on that topic. Yours says that. My
Generac home standby unit auto-cranks once a week and runs for 10
minutes without load. My QuietPack has yet different instructions.

I don't think it matters too much as long as you dry the carb at the
end of the run.

Bob Hatch

unread,
Oct 9, 2012, 12:38:22 PM10/9/12
to
On 10/9/2012 8:05 AM, Neon John wrote:
> On Sun, 07 Oct 2012 14:44:13 -0700, Bob Hatch <bob....@ymail.com>
> wrote:
>
>
>>> Every six months I start and run it for about an hour and then put it
>>> back in storage.
>>
>> I don't think that's what Onan says to do. What does your manual say?
>> Mine says 2 hours per month under 1/2 load.
>
> Mfr's advice is all over the place on that topic. Yours says that. My
> Generac home standby unit auto-cranks once a week and runs for 10
> minutes without load. My QuietPack has yet different instructions.
>
> I don't think it matters too much as long as you dry the carb at the
> end of the run.
>

Because I never put my MH into "storage", I did the 2 hours per month
before I went full time. I would take the MH out on the freeway and run
it for about 50 miles or so, call the Round Table Pizza and order a
pizza to go. We would then pull into the lot with the genset running,
and run an AC and an electric heater in the winter, or both AC's in the
summer, have dinner and put the MH back in the pole barn.

Many times while on the road we would run the genset and roof airs in
hot weather, or Mary would put dinner in the crock pot and let it cook
from one stop to the next. :-)

I have just under 1,000 hours on my genset. I know folks that like to
brag about the low hours on theirs. All that says to me is they have a
problem waiting to happen.

Nice to see you back.
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