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Topic: Onan HDKAK 8KW GENERATOR in 2003 intrigue heat sensor (Read 1241 times) previous topic - next topic
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Onan HDKAK 8KW GENERATOR in 2003 intrigue heat sensor

Yahoo Message Number: 104148
I need help replacing heat sensor that broke off when taking it out.

Ken

Ken Channell

Your Talent Coach

DL 469-853-9682

Re: Onan HDKAK 8KW GENERATOR in 2003 intrigue heat sensor

Reply #1 –
Yahoo Message Number: 104152
Hi Ken,

Search on IRV2 for poster FIRE UP, he owns a Journey. He has some great shots on his process for repairing a few things on his same generator, including a broken temp sensor. A very common thing to happen:)!

It's a matter of drilling, and then tapping out, the old sensor. If this is not something you're comfortable in doing, then look for a shop that or mobile tech to come help you with this.

Best of luck to you,

Smitty

04 Allure 31017
04 Allure Sold to a nice new owner! Now enjoying a 07 Magna Rembrandt 45' ISX600 #6775
"We're ONDROAD for THEJRNY!" (Toad and Coach license plates, say Hi if you see us!)

Re: Onan HDKAK 8KW GENERATOR in 2003 intrigue heat sensor

Reply #2 –
Yahoo Message Number: 104153
Hi Ken, I had the same thing happen to me several years ago, the thin brass part stayed in the hole when I unscrewed the sensor. After many tries I finally came up with a fix. I took the old sensor (kinda looks like a spark plug), cut off the plastic about 1/2 inch above the metal part and drilled a hole down through the middle, I then threaded the hole to accept a very long threaded bolt (I believe it was 8/32 x 2-1/2 inches. (You have to drain the coolant from the engine to perform the next operation).This part is a little hazy, because it was about 7 or 8 years ago. I removed the thermostat cover and the thermostat, this gave me access to where the sensor bottom is. I stuffed a shop rag down into the hole where the thermostat is mounted and then I screwed the old (modified) sensor back in and when it was seated, I used the 8/32 bolt as a jacking screw and pushed the broken off portion into the hole and the rag prevented it from dropping into the water jacket. I then slowly pulled the rag out with the broken piece of the sensor. Sound kind of complicated, but it didn't really take that long. I was going to take off the thermostat housing, but if I remember correctly you had to remove a lot of other components before you could get to the three bolts that hold it to the block. I also purchased a service manual from Cummins (Part No. 981-0522C). The manual is available online from Cummins for about 20 bucks. Hope this helps

Earl Densten

03 Intrigue 11554
 

Re: Onan HDKAK 8KW GENERATOR in 2003 intrigue heat sensor

Reply #3 –
Yahoo Message Number: 104154
If there is anything left you can get a wrench/socket on, heat it with a propane torch then rapidly cool it with something like spray penetrating oil. It should come out.

If you broke off all but a piece stuck in the opening, drill it, insert and 'easy out' of appropriate size, heat it, cool it and it should come out.

I anticipated having issues based on reading about others having problems with the probe. I heated it briefly with a little propane torch then sprayed it with Deep Creep penetrating spray. It came out easily.

Gary

07 Allure 470