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ONAN Gen Set won't start

Yahoo Message Number: 117767
Can you help me with the steps I should take in troubleshooting my gen set? It has been in storage for 4 months. I have it now at my home plugged in. It turns over great and cycles but just won't start.

The fuel gauge on the dash is 3/4 full. Yes, it is time to change the fuel filters in the rear, but the engine started great and ran super on the way from storage to here. Maybe the gen set needs a new filter?

It is an Onan model # HDKAK 8KW

Thanks,

John
2003 Allure #30914
__________________________________
2003 Allure 1st Ave 36'
2006 Honda CRV

Re: ONAN Gen Set won't start

Reply #2 –
Yahoo Message Number: 117774
Does that work for Powertech too Mikee?

Greg

2006 Magna Rembrandt C13
2016 Jeep GC toad

Re: ONAN Gen Set won't start

Reply #3 –
Yahoo Message Number: 117775
Mikee, thanks, but that did not work. I have a new fuel filter in hand and the new air filter will be here Monday. I'll try them first.

John
2003 Allure 370 ISL #30914

Re: ONAN Gen Set won't start

Reply #4 –
Yahoo Message Number: 117776
Hold it down until light turns on solid. This is how you prime the fuel system.
Quote
Hold the switch in stop for a minute then start it

Mikee

Re: ONAN Gen Set won't start

Reply #5 –
Yahoo Message Number: 117777
Ray, thanks for the suggestion. My switch inside on the panel to start the gen set does not have a light. Did you mean the one on the gen set in the bay below?

Re: ONAN Gen Set won't start

Reply #6 –
Yahoo Message Number: 117778
On mine both switches have light, do you have any light inside that says it is running normally?

Re: ONAN Gen Set won't start

Reply #7 –
Yahoo Message Number: 117780
Yes, there is a light that is on when it is running. But when I push down on the momentary switch to the "stop" position like what was suggested, the light does not go on.

Re: ONAN Gen Set won't start

Reply #8 –
Yahoo Message Number: 117781
Might have to do it at the genet then to get the indication. You should also hear the fuel pump running too. That's the function of holding down the button.

Re: ONAN Gen Set won't start

Reply #9 –
Yahoo Message Number: 117784
I'm going to change the fuel filter tomorrow first. Then I'll do the fuel pump priming. I had junk in the tank that I think may be gone (algae) and so maybe some made it to the gen set.

Re: ONAN Gen Set won't start

Reply #11 –
Yahoo Message Number: 117786
I doubt sitting would plug a filter, assuming it was running when you parked the unit. You may have a porous fuel line or loose fuel line connection allowing the fuel to leak back into the tank.

When you hold the stop witch can you hear the fuel pump running?

Mikee

Re: ONAN Gen Set won't start

Reply #12 –
Yahoo Message Number: 117787
Either stop switch will cause the fuel pump to run and the glow plugs to heat.

Sounds like it may have lost its prime sitting. Try the stop switch several times then try to start.

Mikee

Re: ONAN Gen Set won't start

Reply #13 –
Yahoo Message Number: 117788
Have you checked the glow plugs? These are low compression diesels and if you have no power to the glow plugs, they are very hard starting if they will start at all. It can be easily checked with a multi meter, but you need to take the side of the generator housing off to get to it. Do the following at the generator:

1. Verify you have power to the strap that connects the 3 glow plugs when you hold the start button and before it starts cranking. If there is no 12 volts present, you have a bad relay or connection. (Note that the primary purpose of the delay from when you first hold the start button and when it starts cranking is to allow time to heat the glow plugs.)
2. If you do have power, verify that you have a good connection at each glow plug. You may have to remove the strap and clean all the connections and then reinstall.

Dennis 2003 Allure 30884

Re: ONAN Gen Set won't start

Reply #14 –
Yahoo Message Number: 117789
Again, thanks Mikee. I'll do that this afternoon. It has always jumped right off when I start it.

But, lately, I've been reading about the wrong fuel lines installed on Rich's Hurricane....and then someone mentioned their get set is also outfitted with the wrong fuel line.

And now mine won't start! ha! I'd hate for that to be the issue. Lord knows how I'd get to where the fuel line attaches to the fuel tank. My Onan is right behind the drivers side front wheel. It does not pull out. Fastened to the coach frame.

Re: ONAN Gen Set won't start

Reply #15 –
Yahoo Message Number: 117790
There is a great troubleshooting section in the manual. The generator will give you codes to help
Run down the problem.
I had trouble with mine last fall, HDKAK model. My code error was 32. It turned out to be a bad
Ground from the battery wire where the cable attaches to the back of the generator.

Bill
2006 Allure 36' 470
CCI #8203

Re: ONAN Gen Set won't start

Reply #17 –
Yahoo Message Number: 117792
Yes Mikee, I can. That is what caused the further hunting....and then I saw the fuel beside the gen set and knew I was getting close. I sure hope I can splice on a new end and get going tomorrow!

Again, thanks for the help!

Re: ONAN Gen Set won't start

Reply #18 –
Yahoo Message Number: 117793
Thanks to all of you again.. I would not have attempted fixing it without your support. I've found the problem. The fuel line from the tank supplying fuel to the gen set has a hole in it 1/2 way back to the tank from the gen set.

Can I cut the fuel line and put a double barb connection in and hose clamp it? I don't have access to the top of the fuel tank.

I'll try and put photos on.

Re: ONAN Gen Set won't start

Reply #20 –
Yahoo Message Number: 117797
I would closely inspect as much ose as you can. Unless you found something that damaged the hose it probably close to end of life.

Re: ONAN Gen Set won't start

Reply #21 –
Yahoo Message Number: 117806

Thanks again for all of your help! I was able to cut our the section of hose that was cracked and leaking. With a double barb end connector and hose clamps, it is back in service.

I was unable to conceive of a way to get to the connection of the hose to the fuel tank...it is right behind the gen set, but you'd have to remove the 8K gen set to get to it....but it may just be worth it.

Has anyone removed their gen set? Mine is bolted in place to the frame of the coach.

Again, thanks for the great advice and encouragement!

John
2003 Allure 370 ISL #30914
__________________________________
2003 Allure 1st Ave 36'
2006 Honda CRV

Re: ONAN Gen Set won't start [1 Attachment]

Reply #22 –
Yahoo Message Number: 117807
I was able to replace the fuel line on our 8K generator by removing the access panel on the forward wall of the front storage compartment and getting my brother-in-law to reach through far enough to make the repairs. For the record, he is significantly smaller than I am and very mechanically adept, but "we" got it done! Avoided having to drop the generator.

Jeff
2003 Intrigue 42ft. Ovation
400 ISL, #11630