Onan 4000 Watt Generator Not Making Power Part 2

We got the new brush block and now we will reassemble and test the generator.
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Due to factors beyond the control of All Seasons Mobile RV Service LLC and Hillbilly RV, it cannot guarantee against unauthorized modifications of this information, or improper use of this information. All Seasons Mobile RV Service LLC and Hillbilly RV assumes no liability for property damage or injury incurred as a result of any of the information contained in this video. All Seasons Mobile RV Service LLC and Hillbilly RV recommends safe practices when working with power tools, ladders, climbing, repairing LP gas lines or appliances, lifting tools, jack stands, electrical equipment, blunt instruments, chemicals, lubricants, or any other tools or equipment seen or implied in this video. Due to factors beyond the control of All Seasons Mobile RV Service LLC and Hillbilly RV, no information contained in this video shall create any express or implied warranty or guarantee of any particular result. Any injury, damage or loss that may result from improper use of these tools, equipment, or the information contained.

[@robertoruz4381]

Thanks for making this video it gave me the confirmation to do the job. I only didn't get the clear view to connect the battery to start and test before installing it back on my rv if you could guy me for that it would be much appreciated thanks again.

[@GregoryPeterson-g5b]

I am grateful for both of the QG 4000 brush replacement videos. Brushes that hard to access, not grateful to Onan for that. I have a question, what is the flywheel bolt torque? I did not catch that specification in the second video

[@matthewarnold8538]

Like brushes for a alternator 😊

[@thorhammer6040]

I called the Cummings dealer in Hilliard, Ohio one afternoon and the parts were ready to be picked up the next day at 8:30am. I was impressed.

[@hillbillyrv]

That’s great service.

[@KevinFuller-sr1uo]

THANKS FOR THIS 2 PART VIDEO, THIS WILL HELP ME ACCESS THE BRUSHES AND SLIP RINGS IN MY ONAN 4000 RV GENERATOR.

[@hillbillyrv]

You are welcome

[@philstreeter9703]

Great video. Thanks for sharing.

[@hillbillyrv]

You are welcome

[@timjohnston9764]

Thanks for the vid. Lots to learn but not sure I will spend to fix the old gen. $1000 will get a quieter gen that I will just have to modify the install. It’s to bad onan has engineered these to be hard to repair and parts are overpriced 10 fold. Thanks again!

[@hillbillyrv]

Parts are stupid price.

[@jsteele42378]

What a great video ( two of them ) ! ! ! I have learned so much from just watching. If I wasn't retired I would work for free just to see and understand repair procedures that you use to repair an item ! ! ! Again wow thanks so much !

[@hillbillyrv]

You could always come out of retirement.

[@jsteele42378]

If you need solar work but I would bet you already know most of this.

[@hillbillyrv]

@@jsteele42378 I haven't done any solar in years.

[@kayaktote]

EXCELLENT videos both 1 & 2. I think this is the last piece of the puzzle to get my Onan Microquiet 4000 dialed in. Thank you for taking the time and making my life a lot easier.

[@hillbillyrv]

It's my pleasure.

[@rafaellopez4568]

Omg .I will take ur advice. I have the same problem on my .I all most spend on computers and much more .I appreciate u making this video. I hope it works.

[@hillbillyrv]

Me too

[@AE-lk3uc]

This is why i like my "Pre Cummins" Onan BFA. Literally unlatch the cover on the Genny and theres your brushes ready for inspection. Made to last and made to be serviced. The newer ones today are made like garbage. Nothing like the name Onan once stood for. 40 years later and mine still runs like new

[@hillbillyrv]

The old stuff is way better for sure.

[@terrywalker9904]

Great job as always, like many things, the fix is simple, but getting to the fix is the headache...

[@hillbillyrv]

Isn't that the truth.

[@mannyjimenez1010]

Great work !!!!!! Man I wish there was a good generator mechanic down here. The last one I took my onan too couldn't fix it . I had a hard time removing it , I took it to him he had it for a mouth and didn't or couldn't fix it.

[@hillbillyrv]

It’s getting hard to get Onan parts.

[@mannyjimenez1010]

@Hillbilly RV yes Sir, and expensive to.

[@calisdad3]

Excellent videos. Wish you were closer.

[@hillbillyrv]

You could always move to WV. ha ha

[@cg60msc]

Have a relaxing Labor Day weekend!

[@hillbillyrv]

Thanks William, but I am working Monday...yuck !!!

[@redc8783]

Dam another fine mess you got your self out of. 😜😜 To bad Cameron was laid up he miss a good learning experience. Wishing him a speedy recovery 💪🏻👍😎

[@hillbillyrv]

Thanks Red

[@cpt240]

Thanks for the training because mine is doing the same thing

[@hillbillyrv]

I hope you can get it fixed.

[@christopherkanuk2546]

Thank you for your knowledge well done

[@hillbillyrv]

You are welcome.

[@locopilot1]

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.

[@hillbillyrv]

lol....thanks locopilot1, that is awesome.

[@SWFLJetSkiRiders]

I love u man.

[@hillbillyrv]

Ok........don't tell Mrs Hillbilly

[@firedog1116]

Very interesting and informative. Great job!

[@hillbillyrv]

Thanks

[@susieingle3695]

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.

[@virginiareeder9961]

Nicely done...

[@hillbillyrv]

Thanks

[@thorhammer6040]

To get the air box of mine I used a pair of plyers on that bottom bolt and slipped the front half off then slipped the back half out past the fuel pump.

[@hillbillyrv]

Awesome

[@thorhammer6040]

@@hillbillyrv mouse chewed through the brush wire.

[@patricklions9066]

Great video

[@hillbillyrv]

Thanks

[@daviscrt]

Damm, you are the man. Don

[@hillbillyrv]

I get lucky every now and then...just happened to catch it on camera this time.

[@TheDeadwood11]

Craftsman isn't what it used to be. Sure is sad to see them on par with harbor freight ratchets. 2 kits an swapped 3 1/4 ratchets out for the same issue. Bran new crapsman kit an broke the 3/8 ratchet on a fan shroud nut. 5lbs trq maybe? But thank you for informing on where to warranty em as sears an Kmart are gone here.

[@hillbillyrv]

Sometimes Lowes will give you a little hassle, but they are the Craftsman retailer now, so they have to warrant the tools.

[@Attohertz]

Thanks so much for taking the time to make this. I'm putting my spec E back together (had flywheel off for rings cleaning) and I can't remember the routing for the 110v black hot wire. Specifically how does it route past the shield with bristles on it? Does it run next to the larger harness below the regulator and control plugs?

[@hillbillyrv]

Sorry, I don’t remember. This video was shot a long time ago.

[@dennisflora2870]

By the way I experienced that same problem with mine when it had 1900 hours on it.

[@hillbillyrv]

It happens

[@coreymerritt7742]

Nice job Kenny you should treat yourself and buy a cordless ratchet from Amazon or harbour freight they are pretty inexpensive 👍

[@hillbillyrv]

That would be nice, but not something that I would use enough I think. I don't really do much "mechanic" work anymore.

[@coreymerritt7742]

@@hillbillyrv I been looking a getting one I do quite a bit of mechanical on my vehicles and also some of my neighbour’s it would be a handy tool I still need to figure out if I really do need it most stuff I do I use mainly a impact I guess I’m just getting a little lazy lol 😂

[@hillbillyrv]

@@coreymerritt7742 It's tools man, go crazy !!!!!

[@howardmoses6280]

Cool

[@severinchayka7578]

Great video, thank you! Even better than great because it's exactly the same model (including spec letter P) that I have. If you could answer couple very simple questions please: 1. When you normally start this generator model do you need to prime it before each start? Even if it was running only 12 to 24 ago? Manual says to prime it basically only if the fuel lines were disconnected or carburetor removed, that's the way it's written there. 2. When you start this generator model how long you crank it with a starter before it starts? When my generator is hot it starts on the very first revolution. However when it's cold it takes 5-7 seconds of cranking before it starts. Trying to see if I can improve that I found that originally carburetor was adjusted too rich (the spark plug had a lot of black deposit on it), so I made it leaner (for 90 degree of the adjustment screw clockwise) and I had thought it might possibly improve my hard start problem, but it did not. Though the spark plug looks much better now. Should I try to look for something else, or cranking for 5-7 seconds is usual for this model? I noted in your video when you started it at the end it also took about 5 seconds of cranking. Thanks again!

[@hillbillyrv]

Just like every carbureted small engine that I have ever seen, they are all different. Some start well when cold, some when hot, Some crank long, some short. As long as it runs and makes power, you are good.

[@brianbiggs3484]

👍👍🇨🇦✌️🇨🇦✌️🔧🔧 Great troubleshooting sir !!

[@pedroVVILLA]

Great video thinking when you turning the motor did you put oil before you turned just wondering my generator do not charge i changed the voltage regulator now it's charging

[@hillbillyrv]

Oil on what?

[@pedroVVILLA]

Sorry@@hillbillyrv miss the time you said you put oil the carboard say no oil

[@IanoftheRVin]

enjoy all your videos. I was just in the middle of a winter-refurb of my Spec H Onan 4000. Was wondering the best way to bench test the load without all that fancy equipment. Any suggestions would be helpful

[@hillbillyrv]

You would just have to hook stuff to it to put a load on it.

[@IanoftheRVin]

@@hillbillyrv what would be the best and safest way to hook something up to it?

[@johnkphillips5581]

Have you had any luck rebuilding the carburetor on one of these generators? Great video.

[@hillbillyrv]

Not for years. Really hard if not near impossible to get the dried up alcohol out of the little passages.

[@grandmofftarkin4762]

Great video sir I’m new to the RV game and I need a fuel pump Same generator you have the green box is trying to charge me over $200 could I use a different brand and is that okay to do so. Thanks

[@hillbillyrv]

That green box costs you, but it will be worth it to have the right and correct part.

[@mafosa8519]

wonder if the gen. could be converted to a "modern controller and avr?"

[@hillbillyrv]

I don’t know.

[@theresaelkins8954]

Glad that’s all it was, but wow, sure was a pain in the neck to get to! Condolences on the ratchet. Any idea if an Onan QD7500 is put together the same way (probably built in 98 or 99). Just curious in case I ever need to work on mine. Hope Cameron is recovering.

[@hillbillyrv]

One that old should have the brushes on the other end where they should be. Is it in a case like this one was? If so, it would still need to come out to access the brushes.

[@tenglundvideos]

I have a QD 6000 (2015) i have an issue with one line at the transfer switch that is only producing 64.4v at first I assumed the tran switch was bad (switch it out) then realized not enough voltage to in gauge the switch my bad. Is it possible that I have the same problem. The generator does run and not showing any code issues?

[@thomaslockley945]

So how would you fix one that only runs. While. Pushing the start button u think it's the regulater rectifier

[@hillbillyrv]

Onan generators won't run if they are not making AC power (unless you hold the start switch). You have to figure out why it is not making AC power.

[@haroldgray457]

Wonder why my gen a onan 3600 lp will only run with holding the start button in after releasing it shuts down checked for dabber nest in vent, oil level shows a 36 code.

[@hillbillyrv]

Usually when an Onan does that. It means it is not making AC power. There are many things that can cause that.

[@greasezert2228]

So what was the flywheel bolt torque spec since you said you looked it up?

[@hillbillyrv]

I might have lied about that.

[@mrbait4026]

How much did the special green box cost?

[@hillbillyrv]

A LOT....

[@thomaslockley945]

I don't think mine would have. A control. Board. It's like a 73

[@hillbillyrv]

Probably not.

[@thorhammer6040]

Mine didn't have the foam (15:47) mine is Spec K

[@hillbillyrv]

Hmmmm

[@dennisflora2870]

The slip rings are copper

[@hillbillyrv]

Ok

[@Eric-fq5wx]

So what was the flywheel bolt torque spec?

[@hillbillyrv]

Just tight enough. 😃 I don’t remember.

[@TheMinnow101]

I've read more than one horror stories on these Onan's. Complicated and expensive to repair.

[@hillbillyrv]

Yes...expensive !!!!

[@jimfloyd7606]

Many times it is the shop saying, "We'll have to pull the generator...blah...blah...blah'' all the while knowing they likely don't need to. In the Micro 4000 the VR, Control board, fuel pump, fuel solenoid valve, Ignition module, carb, spark plug, start solenoid) can all be replaced without removing the generator from RV. Many shops will also throw parts at a problem because they likely don;t have a G-Man 360. Having the G-Man 360 alone for diagnoses would save folks a bundle of money and get them squared away quicker knowing what the issue is and whether they wish to tackle the issue themselves or let a tech do it.

[@marcuscarmouche9023]

Come on Kenny you know what possessed him to dig into the connector it’s called you tube mechanic 🤦‍♂️

[@hillbillyrv]

yeh, I know but still. WHY ????

[@buyastyle]

I missed this 2nd part! While I’m still decide if I’ll need to find a new onan 4K gen and based on your experience and knowledge: if a fuel hose was rubbing the rotor fan until some plastic burning smoke started, what is going to be your first suspect?

[@hillbillyrv]

It really depends on how much burned. If it only needs fuel hose and fan blade. That is not bad.

[@miguelangelguerrerochan4567]

I was wondering if you got a Manuel service of that kind of generator the same as yours mine is 6300w and i want to now the horse power of this generador

[@hillbillyrv]

I don’t know the answer. Sorry

[@SWFLJetSkiRiders]

What's the tork spect?

[@hillbillyrv]

Just tight enough, but not too tight. I don't know what you are talking about. ha ha

[@robertmcguire613]

I have a question about my onan generator. I have noticed on some generators that they are low idle when there is no demand and they idle up when a demand is made such as a/c. Mine is high idle all the time. Is there a kit one can buy to convert it to high on demand?

[@hillbillyrv]

No RV generator that I am aware of has ever had 2 speed settings. They should run the same speed all the time. Portable generators are the only ones that I know of that have 2 speeds.