Onan Generator Repair | Replacing Control Board & Voltage regulator
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- Опубліковано 26 тра 2017
- Replaced the control board on the generator which wasn't the problem so i ended up replacing the voltage regulator instead and cleaned the carburetor hoping it would fix the surging problem.
As of now it needs a new carb or rebuild kit.
.~
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Thanks for watching :) - Навчання та стиль
We have used the ua-cam.com/users/postUgkxOTeIs0vv4_9B5hsmnLsk9r930uDQLu_Y for probably 30 hours with our camper and it’s been great! The noise level is really only noticeable when running the AC and other appliances like the microwave, hair dryer, or coffee pot. It’s not huge like other ones and it has wheels so even at 90lbs, I can move it!
Thank you so much for this video. I just buy rv with same generator that needed fix. God bless you.
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 (it won't start if low oil becouse of sensores), gasoline more than 1\4 tank in the RV (also safety censors), sparkplug checked for good spark, check the manual circuit braker ( to be ON) at front motorhome engine compartment for 12v current to the gen 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 by rats so I replaced them, by this time it started but stay running only by keep pushing the switch on all the time, so I knew it was 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 unit) 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 becouse 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 then put the air cooling assembly back and the rest of components including the cover, now it's ready to be installed at your RV.
Once the gen it's installed back at your motorhome or RV start your gen to be tested for electric power but don't forget to flip the electric switch (on) at the gen electric panel (sometimes hiding under or around the electric controls) to transfer power to your RV GFCI main outlet and electric panel as well, if your it's equipped with GFCI reset it and tested for green led light indicating power is ready at you main breakers panel, flip your main switch (on) along the others ones at this moment if you still don't have power then it's a faulty main braker, flipping it many time sometimes make it work again, mine did it, lol!!! If yours didn't buy a new main breaker.
If this can help eaven one person save time and $$$ it'll make me more happy, thanks for reading!!!
Under that green plastic cap(18:22) is the idle mixture adjustment needle. As the cap is there to keep you from adjusting it (EPA/CARB emissions regulations) and it's still on the needle, you didn't clean the needle and orifice it screws into. Remove the cap, unscrew the needle, then using the spray tube, spray carb cleaner into the orifice. Clean the needle and reinstall it. Lightly bottom it out then back it out 1 1/2 turns. Start the generator and let it run for 5-10 minutes to warm up with no load. If genset is still surging, back the screw out to richen the mixture. Once the surging is gone, load the genset to fine tune for 60hz using both needle adjustments.
Thank you for posting this video. It was very informative and it saved me over $300. Also thanks for the comments. UA-cam university rocks.
I just purchased a new carb hoping to solve my surging problem. If it doesn't solve it, I guess I will try replacing the voltage regulator. Thanks for posting the video!!
Did the new carb solve it? If not, what did? Thx!
@@ericstephenson9924 Absolutely, the new carb solved the surging problem
Man, you are so handy. If we were on the west coast right now, I'd hire you to do some stuff on our rig. Maybe when we get back there. 😏
Also I have worked on generators that have a engine kill switch if the engine is low on oil to keep from running the engine without oil, Again wish you luck.I am sticking with this to see the problem :).
Good video bud, now I get it, a quality video, a good teacher, I cant be on UTUBE LOL
Good job.
It is better to replace the carburetor than to clean it. The surging would be the governor adjustment. If you can hold the throttle still and it runs smooth then it is the governor adjustment. If you hold the throttle still and it still surges or runs rough it is a gas supply problem- carburetor, fuel pump, cracked or clogged fuel line from main tank. Good video though. I have not been able to clean one of these carburetors and have it work right. More cost effective to change it.
this might help someone i had one that did this very same thing.it would start and run but would surge i put acetone in the gas and put a load on it the air conditioner and let it run it straightened out either run a gas can with acetone and gas in it or put the acetone in the gas tank run it, about 10% acetone . if you can clean the float bowl out that would be a plus. its worth a try like your videos you definitely think outside of the box
As it was running I figured it has got to be the jets or something hampering the fuel and air flow. stick with it you almost got it.
good job on all the info
I had a Winnebago class c, years ago I seem to remember my generator being on a slide out tray for easy access.
If you had dialed the altitude dial to the left, it would've stopped surging. Set at lower elevations increases the amount of fuel for fuel to air ratio. I have a Genset 1 that had the same issue. It's only the voltage regulator from what I could see and diodes should measure one way @ 0.52V ish You're voltage regulator is probably repairable if you just swap out hat 220uf 400WV Capacitor.
what was the initial problem? why were you changing the board and regulator.
Mr.Wrench. try runing seafoam in the gas line. Had same problem. Running smooth now
Man did you ever finally get the generator running smoothly. I have the same problem with my generator and wondering if I should spend the money on it
I have a 7500 onan on a motorhome and it just out of a sudden wont start. If gives me code 19 which says governor actuator fault. controller sensed open or short circuit. Any ideas.
Thanks
Great video. I keep referring to it for troubleshooting. Genset was shutting down when releasing the start switch. Found a short inside the voltage regulator. Fixed it. Good job!
I recently started my gen to start my main engine with jumper cable from coach batteries and started main engine andv5 min smelled somthing electrical at gen and now it starts but wont stay running? You have any ideas..
I hope I am over looking at all or sound slow or something, but I was having the same problem. what I understand is that some onans have a security switch called a sip stick or something. it wont run if your tank is 1/4 gas or below. I would try filling to 1/2 tank or better just to make sure its not that.
Where would I find the serial number to replace the control board please
You were missing the fuse on the old board... the new o mb e came pre assembled with a pot tube
where did you get the voltage regulator?
great video 🤘
Your hired good job
Hi Mate great videos
Everything but the rectifier. Mine keeps blowing main fuse. Where is it located?
My genset emerald 1 turns over with engine switch but not with the switch inside the r.v.has no fire at the spark plugs.any suggestions
you have to continue to hold the start button in after it starts for a few seconds till oil pressure is up, they have a safety cut off so that ignition goes off if no oil pressure. if its full of oil and wont stay running when the start switch is released then its probably the oil pressure saftey switch thats bad.
This, or that no oil switch has give up the ghost. Easy to wire around it to test.
I have a onin marquise 5000 generator in my rv that will only stay running if I hold the start button down. What do you think it could be?
@@kylestillwell261 sounds like it's just cranking. Try to check the fuel lines, fuel filters etc.
You should have cleaned the idle circuit jet on the carburator. located under the idle speed adjusting screw.. That would fix the problem
What is the model number of that generator. I have one just like it and have to order parts that are missing from the previous owner
Idle spring needs more tension...the surge will smooth out then
where can i get the control board ?
I have a 4010 Honda in mine. It starts but dies out 3 to 5 mins later. If I hold the start button will keep running yes I know it's not good been times I've gotten really mad. I once hit it all over the motor with a hard rubber hammer got lucky it ran for over two hours. Yes was told to disconnect the yellow wire still does the same thing. Yes new oil and oil filter fresh antifreeze still cuts off. Any pointers ?
Check your oil pressure, might be low on oil or your oil pressure switch could be bad.
Can you put the links to purchase in the comments or descriptions
That bottom left thing has the 12 prong connector... what is that? Mine is missing
you needed to adjust the screw on the bottom of the carb.
second you gotta check the output make sure it's about 61hz, the engine speed is can change your output.
You have to adjust bottom screw and top idle screw !
Did you ever get the generator fixed/running correctly?
Not yet, wasnt going to put anymore money into it so it's on hold for the time being
the diodes aren't big enough to actuate the relays on the original boards. that not withstanding I have seen tons of videos where people waste money on a new board since the start button issue persisted afterwards. I saw one video where a guy had the relays on the original board replaced by a TV repair shop (where the hell is one of those today????) and it fixed the issue. I just got a camper with one of these generators and it has been a pain in my ass. does the start button thing.
SURGING (as Walter said below) is symptom of LEAN; you removed, but did NOT disassemble/ clean HIGH SPEED MIXTURE/ ALTITUDE SCREW in bottom of float Bowl? (You Might have) been able to do that without removing carb? (But I do appreciate the video of carb/ bowl/etc); 1-1/2-turns is pretty standard, but does not compensate for YOUR altitude, was the plastic cover ON the altitude adjust or had (you/PO) previously removed? I would have (closed/ recorded #-turns) on main jet adjuster for later reassembly. Had you ever tried just adjusting HIGH SPEED with plastic cover removed? I suspect this high speed screw/ jet was the carb issue, (assuming fuel pump delivering enough fuel to maintain proper fuel level?) You want all jets/ fuel passages clean/ shiny
that thing probably has a cylinder way in the back, somebody correct me if i am wrong, but can a cylinder down cause it to surge like that?
Any chance you could help me put with a serial nu.ber this one I got is totally ruined
were did you get your parts do you have a link you can share with me
Erik Karadeema the small white wire underneath there is connected to a green wire...when I run a wire from that green wire to the battery under hood mine cranks right up and runs..is it safe to just run a wire from the green wire to battery and leave it that way
First mine wouldn't start ( dead - using both start switch's) ..then after pulling the fuse and flipping the breaker off/on it started but no power to the coach. The breaker feels really limp and doesn't have a good solid "CLICK" feel to it...I see there is a voltage regulator also huh 🤔
I would like to know where u got the parts that u replaced! The Board and the voltage regulator? Pleaser!
the place is called flight systems inc, they make control boards for onan generators.
surging problem if you try carb spark plug and cap and vr and still surging might be a gummed up value
when you scrap your RV be sure to keep this generator its worth a good bit
Electrolytic capacitors dry out over time...especially with non use. Best way to avoid this is to exercise generators under load at least 15 mins every month. Keeps carbs clean....run seafood all the time as well.
Mmmmmm, seafood.....
LMAO that idle good job good video though.
Thx my man great video it helped
The vacuum line might be leaking can cause serging
Does anyone know how to get two phase power out of a Marquis 7000?
No such thing as two phase. It's either single phase, or three phase. And a 7000 is not capable of three phase. Sorry!
they're referring to 240 volt single phase. I'm wondering too if this is possible, but I wont know until I open her up and check out the insides. mine does have 2 separate 120 volt circuits, which if in the same phase, may be possible to wire for 240 volts.
btw, 2 phase really is a thing, but has always been rare. what we use today in our homes is 240 volt single/split phase.
How do u test it pleas n tanks
Can you come over and help me fix my RV my generator ain't starting up what city are you in
That generator is in a condition that is called ( hunting) it needs the governor adjusted so it runs smoothly, the take your voltage meter, and check your 110 voltage at the receptacle s inside your coach,if it's above 110 volts then lower your engine speed ,if it's under110 volts then increase your engine speed till you reach 110 volts,
were can i order a new board
Ebay
(Sorry, late post) you fried all the electronics you had plugged in while doing this? Ouch, that sounds like a very expensive lesson that you probably never repeated!
Nope, i tore the Onan out after that. Problem fixed! :D
Mine runs but no power is that what was wrong with yours. Mine runs really good
sorry to say I wish I seen this sooner I would have told you cleen the carb #1 thing to do with a no start small engine 😣
Doesnt matter, i cleaned it and didn't help.
@@ClassALiving that sucks those can be great when they work but when they don't there tuff 😣
What is the model number on that unit
6.5NHEFA26100D
take it in............
did it run before you put the voltage regulator in it?
ervdawd8 nope
I know when mine did that it was the screw at the bottom to regulate the fuel. how much did yiu pay for your voltage regulator?
Need to Fuel
k
Maybe if you had a fuse in your old circuit board it might have worked fuses missing when you take it off so it couldn't have worked without it LOL
I would just take the fuel bowl off next time or run non ethonal fuel before winterizing
#1, by all means build a heavy ass compac pile of junk and put it in a compartment you can't see or feel your way too analyse a thing in a motorhome so when your miles from your floor jack and tools it breaks down on you. You betcha! You got a boat ANCHOR.
Looks like the fuse was missing off he old board
:)
Bad... Rubber hose right next to things that go "spark." 5 bucks to plumb to the fuel pump with steel.
already know why is running like that, it needs to have the electronic choke replaced
Gotta admit, I went a couple of minutes going "you're not gonna clean it?"
Should have kept watching sorry for the question
I hate Onan !! Everything you touch is 300 bucks, They took a simple task and found the most complicated way of achieving it, horrible design. Gimmie the new Genny converters any day.
Did you see the old board didn't have a fuse lol
Danny Yarbrough ya dude u so smart, good job, wow
Idle jets are clogged.
HIGH SPEED JETS CLOGGED; gens don't much idle
The sponge around your air filter should have alight coat of oil.
should have? oil blocks air flow. oil on air filter is bad
You should have stuck with the same fuel pump that was on it.
You should pay more attention
I cut my teeth on the ck 4000 onans..they were simply the best...then emerald put the screws to them...then Cummins put the final nail in the coffin..i have rebuilt a few control boards for just a few dollars in parts. Onans are the best, however parts will kill you in price
Absolutely don't ever use a wire brush on carburator part. All the brass parts will never be the same.
$ 290 will fix it, just bite the bullet.
what a rats net of wires
The carb is always the first thing to clean with the new fuel issues
This video is completely misled the procedures has nothing to do with the labelling of what the repair will be ?
What a mess!
Gotta charge the battery from a mains, just too TRY and start that so called convenient off grid piece of crap. If America ever educates this Generation,, we might have reliably minded engineering AGAIN!
Junk Onan. Buy a cheap harbor freight predator. Problem solved
This is what mine is doing, hope ya find an answer before I buy a throw away Chinese piece of crap thats lighter simpler and cheaper!
scrap it
sean barrasin agreed
man, stop biting your fingernails
Ugh, i was thinking the same but imagine the stress at the time living in a rv with no genny.
I could swear i could hear the chirp of a fan belt the whole time the video was going.
Like poor guy idiling a big block for 12v power bahahaha