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Onan GenSet - project rebuild


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  #21  
Old 06-20-2017, 09:33:08 PM
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Default Re: Onan GenSet - project rebuild

Leon as Billy alluded to if the batt is charging it means the field is being excited which means that the voltage reg is working . Since the excitation power comes from the main windings it is pretty much a given that the set is making power. Cheers Dan
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  #22  
Old 06-21-2017, 06:26:51 AM
Leon N. Leon N. is offline
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Default Re: Onan GenSet - project rebuild

BBCHev yes I know. But who knows what abuse these machines may have been through. My thought was there could have been a problem with the stator power windings and not the charging winding. Yes, kind of unlikely, but who knows. Point being some of these machines employed a totally separate AC power source for the charging circuit, but used the common field exciter.
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  #23  
Old 07-11-2017, 12:56:27 PM
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Default Re: Onan GenSet - project rebuild

Okay the refurbish is coming along nicely, still trying to pickup parts as i go. I have a question on the plugs. it has champions and i don't recall what they are off the top off my head. Anyone know which will fit? In the parts manual, it shows plugs or resistance plugs.
Also the side panel that was missing, it shows two possibilities in the parts book, online it shows 3 . 134-1096, 134-1202, 134-1039.
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  #24  
Old 07-11-2017, 03:26:20 PM
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Default Re: Onan GenSet - project rebuild

I would try to find a NGK or Autolite/Motorcraft equivalent. Champion plugs are not the best quality. They like to seize up in aluminum cylinder heads. Learned this 40 years ago when I worked at a VW shop.
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Old 07-11-2017, 06:52:37 PM
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Default Re: Onan GenSet - project rebuild

Quote:
Originally Posted by gmdoctor View Post
Anyone know which will fit? In the parts manual, it shows plugs or resistance plugs.
OEM plugs were likely Champion H8. This will cross to a Prestolite 216 or several others.
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  #26  
Old 07-20-2017, 11:44:55 AM
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Default Re: Onan GenSet - project rebuild

Cool thanks, Yes they are H8 and they are probably the original set seeing that this thing never had much maintenance done to it. But they came out after a good soak. I finally got the last two rusted exhaust bolts out of the heads. It took me using a new product out where the spray literally freezes the bolt and you hit it with a hammer. then they walk out. the penetrating oil smells like crap, but it worked! Today i can go pick up new studs and i can start putting this thing together again. Last night i drove 4hrs to pickup another Onan set, but this one was a turn key. I had someone tell me about this as it was removed from a horse trailer, but the guy was going through multiple bottles of propane at a time. So i now have a 4.0BFA-1R/16020C C843755504. It looks like i now have a small backup set. Any info on this little guy?
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  #27  
Old 07-20-2017, 02:08:35 PM
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Default Re: Onan GenSet - project rebuild

Congratulations on your new addition. Built March 1984. Manuals available at the twinslan link. See post #4.
120 volt , 1 phase , 2wire. Remote start.
Ray
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Old 07-20-2017, 02:40:48 PM
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Default Re: Onan GenSet - project rebuild

Thanks Ray
Looks good runs like a swiss watch. well maintained. tested well, they had it connected to a rodeo show down here running virtually everything, but kept running out of propane every 2 hrs. But they were using 20lb propane bottles for a grille.
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Old 07-20-2017, 04:14:45 PM
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Default Re: Onan GenSet - project rebuild

Quote:
Originally Posted by gmdoctor View Post
Thanks Ray
Looks good runs like a swiss watch. well maintained. tested well, they had it connected to a rodeo show down here running virtually everything, but kept running out of propane every 2 hrs. But they were using 20lb propane bottles for a grille.
Proving once again, that, depending on ambient temp, you can run a BF, NH or a BFA fully loaded on 40LB propane cylinders.
BTDT
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  #30  
Old 07-20-2017, 05:10:15 PM
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Default Re: Onan GenSet - project rebuild

^ Or proving that when a 20 pound tank freezes up after two hours, it looks a lot like an empty tank to some people.
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Old 07-20-2017, 05:40:19 PM
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Default Re: Onan GenSet - project rebuild

Yes likely froze

7NHM consumes propane @ ~ 1.5 gal/ hr at full load, so guessing a 4.0BFA takes 1 gal/hr MAX. MAX MAX.

20# BBQ tank holds ~ 4.5 gal , and they fill to ~80% ( 3.6 gal) so if kept tank warm one tank should run 4 BFA ~ 3.6 hours. Not only 2 hours

Maybe a fan will help

Last edited by len k; 07-20-2017 at 07:02:36 PM.
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Old 07-21-2017, 07:04:43 AM
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Default Re: Onan GenSet - project rebuild

once again, this guy just wanted this set removed from his trailer as he had purchased a newer and much larger gas model. Which was good for me! So to be exact on how much was consumed or used or frozen (which has happened to me) i cannot be sure. I just repeated what he had told me. So this weekend i will test this. As i set it up, i will report back to here and try to validate his story.
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  #33  
Old 07-21-2017, 06:07:25 PM
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Default Re: Onan GenSet - project rebuild

Quote:
Originally Posted by len k View Post
20# BBQ tank holds ~ 4.5 gal , and they fill to ~80% ( 3.6 gal)
LPG weighs 4.2 lb per gal 20 lb tank is 20 lb at 80% 4.7 gal
Most 20# tanks that you get from places like exchange racks only have about 2.5-3 gal in them
Get your tanks refilled from a good LPG dealer and you will get 4.5-4.7 gal

Butch
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Old 07-22-2017, 04:11:07 AM
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Default Re: Onan GenSet - project rebuild

Cylinder Capacities in Gallons and BTU's
Size 20#
Gallon Capacity 4.8
Total BTU Capacity 441,600

Using these factors we can arrive at run times based on average load for any generator.
For instance:
How long would a 5000 Watt Generator with a 10 HP engine at 50% load run on a 20# propane cylinder?
10hp at 50% load would be using 5 horse power to generate 2500 watts of energy.
5hp x 10,000 btu would consume 50,000 btu per hour.
Using a 20# cylinder that produces 441,600 total btu, the engine consuming 50,000 btu per hour would run for about 8.8 hours.

************************************************** ************************************************** ********************

20# Tank

Maximum Continuous Draw In BTU Per Hour -

@ 0 F - 36,000 BTU

@ 20 F - 51,000 BTU
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  #35  
Old 07-24-2017, 07:03:02 AM
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Default Re: Onan GenSet - project rebuild

darn weather was so bad here this weekend, i couldn't even open a garage door. Still on weather hold
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Old 09-11-2017, 09:27:54 AM
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Default Re: Onan GenSet - project rebuild

Ok guys, finally i was able to test this guy. #20 tank did run the little guy but not before i ran into multiple issues. Had multiple leaks i had to repair, then adjusted the carb to gain max efficiency. Then electrical issues arose as the test continued. The person before me had a RV female plug in an electrical box and then a second box attached to it for a regular 120v receptacle. i had started with the 120v rec. for a small load for 30min. i didn't run an amp meter since it was a first run. more of just seeing what it can do. next i went to plug in the 30amp RV receptacle, killed the generator. would not restart, i unplugged the recp. and it started back up. found the recp. was shorted. since i didn't have a spare and was running out of time, i used the 120v rec. i ran a bunch of cords to a large power strip i use for Christmas lights i made years ago. i put everything on this generator i could throw at it. 2 large refrigerators, a larger deep freezer, 2 5000btu window a/c units, every light i had available in the garage ( 8 8' florescent bulbs), one large high volume floor fan used in my shop. total just over 5k watts. i only ran full like this for a few min and added things one at a time. total run time was just over 3 hours when i shut everything down. Still have the small #20 tank with fuel, but very little. now that i have the bugs worked out, my next test i will use a load bank and an amp meter and a better tank. I failed to weigh my propane tank before i had started.
next test i will set a better reference table and have everything working correctly. On another note, my 15k JC unit i have tried to refurbish had a major failure. i never touched the engine other than to clean, repair broken bolts, replace small gaskets and hoses. i started this big guy up hoping it would be the last of my worries during the current hurricane. it didn't run 30 seconds when i noticed oil spewing from the rear head area. This thing has a blown head gasket!! ok now i need a head gasket, i know you gave out the Onan link for getting parts. But i spoke to someone there and even sent them my email with what i needed. i never got a call back, and i received an email over 2 months later stating no parts available. So again does anyone have a lead on Onan parts? My local RV center sees me as a gold mine, charged me out the wazoo for the parts they could get. many places on the web also advertise parts, but cannot get them.
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Old 09-11-2017, 10:26:59 AM
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Default Re: Onan GenSet - project rebuild

Try "Onan Parts" who is a sponsor here at The Stak.

Are you sure it is a head gasket? I would pull the valve covers and check torque on all head bolts before I pulled the head.
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  #38  
Old 09-11-2017, 11:00:29 AM
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Default Re: Onan GenSet - project rebuild

Most people use hair driers and space heaters for load.
~ 1500 watt each gets you to full load fast.

Propane tanks have their empty weight stamped on top ring, labeled TW (tare weight). New 20 # tank is usually 16.5 to 18.0 pounds. That's how I sort out which tanks are empty before refilling. I use an old accurate scale someone threw out, has sliding weights.
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Old 09-11-2017, 12:03:09 PM
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Default Re: Onan GenSet - project rebuild

As mentioned try "OnanParts" or, I just called my local Cummins/Onan dealer,

For part # 0168-0208 which is a valve grind gasket set for a JC, has both head gaskets and all related gaskets, valve stem seals and what not, it's $87.00. Mind you they have to order it and would take about 2 weeks.
The two weeks is just bringing it in on a normal stock order and no freight charges, if needed quickly, I'm sure they could get it AT an additional charge!

Last edited by nothingbutdarts; 09-11-2017 at 12:06:43 PM. Reason: added info.
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  #40  
Old 09-16-2017, 10:56:22 AM
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Default Re: Onan GenSet - project rebuild

Max i ordered the head gaskets and will pull it down probably later today after work. yes i know for a fact its a head gasket. i can see where the head meets the cylinder its coming out.

i ordered the head gaskets from cummins through a dealer who sells cummins products. i had previously ordered multiple gaskets for the engine but never got the head gaskets. now i have the entire upper end kit. but i pieced it together instead of a grind set. cost was higher but got to the same conclusion.
anyone looking for a 4.0 BFA? i don't know any numbers off the unit, but since I've been playing around with these two i have had multiple people wanting to get rid of theirs. mostly from collecting dust and no understanding of the units. people just want a turn key unit now. I have no use for a second 4.0 BFA.
I do however have a lead on an Empire 50kw unit with a 6 cyl cummins unit cheap! worked when pulled. backup for a small store. Anyone with knowledge of these units from Wisconsin? Model 500DFW-8E Serial 380-106
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