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Onan Gen. 8k shut down?

Yahoo Message Number: 98602
I went to run my 8kw Onan gen. but it started and ran for about 1 min. and shut down. I changed the air and fuel filter with no change. First code was 3-3 and the second code was 3-6. I cracked the fitting at the fuel injection and have fuel at the fuel injection. Oil level is good and coolant level is ok. Any ideas would be welcome.

04 intrigue 400 cummins
#11725 36 ft.
Onan 8HDKAK11451H

Re: Onan Gen. 8k shut down?

Reply #1 –
Yahoo Message Number: 98603
Check you radiator coolant level as the first step Mark and Denise Laser
Newbies

Pick up our CC tomorrow
mark

Re: Onan Gen. 8k shut down?

Reply #2 –
Yahoo Message Number: 98604
look at the Country Coach Owners Yahoo site. Seems code 33 is a temperature sensor issue.

Buddy Bordes

06 Inspire #51887

Re: Onan Gen. 8k shut down?

Reply #3 –
Yahoo Message Number: 98605
Lower the front end of the coach to make sure the fuel runs down hill to see if this makes a difference.

Craig Spiess

2007 Inspire 360 #51959

2005 Honda Civic Hybrid 4 Down

Re: Onan Gen. 8k shut down?

Reply #4 –
Yahoo Message Number: 98606
ENGINE STOPPED FAULT CODE NO. 36 (Engine stopped without command by controller)

  • Check fuel level. (Note: The genset fuel pickup is probably higher than the vehicle engine pickup.)
  • Prime the engine fuel system if the genset ran out of fuel (p. 4-1).
  • Check for fuel and air leaks at each fitting in the fuel supply line. (Note: White smoke indicates air in the fuel.)
  • Check the engine air filter and remove any blockage.
  • Check for mechanical damage.
  • Check auxiliary fuel pump (if equipped).
  • Conduct a fuel flow test and service as necessary (p. 14-1).
  • Remove the front and top housing panels (p. 6-4) and disconnect engine harness connectors P1 and P2 from the controller (p. 19-1, 19-4, 10-2). Check for missing, bent or corroded connector pins and faulty wiring and repair as necessary.
  • Service the engine (p. 12-1).

Re: Onan Gen. 8k shut down?

Reply #5 –
Yahoo Message Number: 98607
HIGH ENGINE COOLANT TEMPERATURE FAULT--CODE NO. 33 (Engine coolant temperature exceeded design limit) Corrective Action:

  • Check the engine coolant level and add coolant and repair leaks as necessary (p. 9-1, 12-1).
  • Check for and remove any objects blocking the air inlet or outlet openings in the bottom of the genset.
  • Reduce the number of appliances connected at the same time. (Note that high altitude and high am- bient temperature decrease engine cooling capacity.)
  • Look for a broken or worn coolant pump drive belt (p. 12-3) and replace as necessary (p. 12-1). (Vis- ible through the maintenance access door in the skid-base.)
  • Remove the air intake grille in the skid-base and check to see that the cooling blower (p. 11-1) is secure and that the blades are not fouled.
  • Check for air leaks in the housing--missing or loose housing panels and access covers, including the access covers for the fuses and AC terminals.
  • Clean and flush the cooling system to remove coolant passage fouling.
  • Remove the top housing panel (p. 6-4). If loose, reconnect engine harness spade terminal connector E3-1 to the coolant temperature sender (p. 12-1, 19-1). (If the lead is loose and touching ground, the controller will sense a high engine temperature.)
  • While the top housing panel is off (Step 8), check for fouling of the radiator air passages and clear out dust and debris with compressed air directed from below (reverse of normal air flow).
    Wear safety glasses when using compressed air to prevent severe eye injury.
  • Replace the coolant thermostat (p. 12-1).
  • If the genset overheats only underway, see the coach manufacture regarding air baffles or other means to direct cooling air into the genet.

Re: Onan Gen. 8k shut down?

Reply #6 –
Yahoo Message Number: 98608
One thing I discovered when I had the same symptoms is there is a belt on the water pump. Ours broke and caused the overheat after a few minutes, It can be seen via the access panel and looking to the very rear. I thought I was told it should be changed every 400hrs or something like that .

Re: Onan Gen. 8k shut down?

Reply #7 –
Yahoo Message Number: 98609
Thank you for the ideas, I will check out temp sensor since I had one go bad about 4 or 5 years ago. My main fuel tank is full and it looks as if I am getting fuel. The belt is turning and has been replaced. The air intake is clear and fan turns while cranking.

Lowell

#11725 Intrigue 04

Re: Onan Gen. 8k shut down?

Reply #8 –
Yahoo Message Number: 98610
Soon after we purchased our coach 4 yrs ago the gen. stopped working.  It would run for a minute, than shut off.  Took it to a Cummins dealer in Salt Lake City.  He found that the actual t-stat had broken.  According to Cummins,  generators must be run on a regular schedule or the antifreeze will actually start corroding the  t-stat.  The housing for the thermostat also had started corroding and had to be replaced.  Hope that is not your problem, but it did happen to us.
Tom

2005 Inspire 51177

Re: Onan Gen. 8k shut down?

Reply #9 –
Yahoo Message Number: 98611
Mine was completely gone through including new radiator, sensors, belt, hoses, T stat etc. it continued to shutdown and was removed again. After many tries it was a defective radiator cap. Cheap to try.

Re: Onan Gen. 8k shut down?

Reply #10 –
Yahoo Message Number: 98612
That is one great piece of BS, Tom.  I have replaced 100's of  T-stats. In all the years never have seen a corroded T-stat,  broken ones,  yes.

By broken I believe locked in position.  Another question ...if the housing is corroding, sure raises a red flag.  What  were the results of the antifreeze test ?

Some of the stories these service guy's tell are pretty  good.  Only to be out matched by there billing.

Onan Gen. 8k shut down?

Reply #11 –
Yahoo Message Number: 98725
This will repeat what others have posted, but wanted to share my findings on this era Onan.

-Temp Sensors were not a good design. They were prone for going out, and due to material differences, the male threads of the TS would 'meld' into the different metal compounds of the female body threads. Onan came out with a replacement TS about 3-4 years ago, that was supposed to be an improved design. (This was from a conversation with Onan Tech Support.)

I replaced mine twice, with the second time moving to he 'new' TS. The parts supplier had to work hard to find this, as the older TS were not pulled out of stock. Due to this being the second time for me, I did not want to be without a generator due to a false sensor reading. So I had a second TS wired into an A/B switch. (A is the stock TS.) The second TS is C-Clamped to the outside of the metal thermostat housing. If the stock TS goes out again. I'll carefully inspect fluids, and also the fan belt. If all looks good, I'll change over to B, running the generator via the external TS. This way I can finish a trip, and do the change out of a possible bad TS unit on my schedule and location. (Gang, message here is to not do this blindly. Do get out and check over the generator carefully, before considering bypassing the stock location TS as I have incorporated.)

-Many 2004-2005 and earlier coaches, had fuel lines that were not able to handle the switch to ULSD fuels. They will break down over the years, and could result in fuel leaks (fires) are problems on feeding the generator and or hydro hot.

Recommend preventative maintenance with a ULSD compliant fuel line. I went with Gates Barricade, but Napa and others have good compliant fuel lines.

Also as info sharing. On our final change of the TS, and the adding of the second TS unit. We had the Radiator, Thermostat, and related components replaced at the same time. The previous owner did not exercise the generator, and service of the radiator fluid was lacking too. The radiator could not even be serviced to be used again. Along with the new radiator, we went with Final Charge coolant (Changed the Engine Radiator to this at the same time, and wanted both to be running the same coolant.)

On our era or coach, no slide for the generator. So I spent a bit extra money on the fan belt, and got the best Gates highest quality fan belt I could find. (Just looked for the part number, and dang if I can locate it, sorry.) As the service of the belt, and generator in general, is a PITA in this coach.

I do strongly recommend following the advice of many on this and many boards, to exercise your coach and generator regularly when not in usage. We get out and do a run, including the generator under load, once every 4-6 weeks.

And I'll second the other feedback on how a simple radiator cap, can cause problems. I placed on my maintenance schedule, both the engine and generator caps to be replaced yearly.

All of this is now about 20 months ago, and the generator has been running solid after all of this work. I do feel the exercising of the generator, is a key part of this...

Best of luck to all, have fun, be safe,

Smitty
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 Gen. 8k shut down?

Reply #12 –
Yahoo Message Number: 98726
thanks for the info.  We also had to change our fuel lines. Our generator wouldn't start and had a code not getting fuel or air in fuel line. Cummins in Montgomery AL found a pin hole in the fuel line. They said that the hoses were not even fuel grade hoses. We replace the hoses to the generator and Hydro Hot.  We had the belt replaced at Cummins in Kansas City and they did so without removing the generator. We later had the generator serviced at Cummins Coach Care in Tulsa. They removed the generator and when they replaced it they bolted it in, not welded.  If we ever need service again we can remove the bolts and drop the generator. All 3 of the above listed Cummins locations are excellent. We do also exercise our generator monthly for about an hour and we service it annually.

Lonny & Diane Livingston
'04 Allure #31065

Re: Onan Gen. 8k shut down?

Reply #13 –
Yahoo Message Number: 98794
My gen. problem turned out to be the fuel lines. I did replace both gen. and hydro hot lines and everything is running fine again. My gen. did have to come out to be able to get to the top of the tank. Gen. is on drivers side just behind front wheel (no slide).

Thanks for all the feed back
Lowell Johnson
04 Intrigue 36'
2014 CR-V