ONAN EMERALD PLUS 4000 GENSET July 09, 2017, 12:34:43 am I am having a problem with my Generator. I changed the Oil and Filter last month along with the air filter. I started it up today and it would only stay on for 5 mins. So, all day long I would restart and every time it would last another minute longer. Here it is 9:30 pm and it lasted this time 20 mins. before it stopped. Any help would be appreciated. Leaving next week to Yosemite
Re: ONAN EMERALD PLUS 4000 GENSET Reply #1 – July 09, 2017, 01:21:27 am First check the oil level. It has a safety switch for low oil. Check clean and gap spark plugs. The older Emeralds have a strainer in the bottom of the fuel pump, is it dirty?Second check the condition of the fuel hoses, pipes, and hose clamps from the tank to the generator. I replaced some. Third, how long has it been sitting un used. Mine sat for 3 years on shore power. Generator unused. I had to turn off the generator circuit breaker CB1-30A and manually force the governor to 2000 rpm to force it to use gasoline and hopefully dissolve the gum that may have formed in carb for 10 min. Then let it run normally on the governor. Shut down generator. Turn generator circuit breaker CB1-30A back on. Restart the generator. Check AC voltage. Adjust governor speed to get to 118 volts. The transfer switch opens at approximately 105VAC. I also turned off the Air Conditioner Circuit Breaker through all of this. The generator stabilized. And prevented brown out damage to the air conditioner. The generator was stable after 5 hrs of run time, a transfer switch replacement and AC on. Note: The 3 years on shore power and intermittent generator also played havoc with my old transfer switch. Which I had to replaced. 1 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #2 – July 09, 2017, 10:31:41 am Thank you Rodney, I finally got it to run for 1 hour last night. I did a check on oil and lines. I even added a little bit of water in battery. I do start it up once a month. Never had a problem until now. The pictures are from when I bought it last year. I've cleaned it up as best as I could. When I changed oil last month I held back one quart and did add that yesterday when I noticed level was not on stick! Thank you for your reply. I am planning on running it today for a couple of hours and see how it goes.
Re: ONAN EMERALD PLUS 4000 GENSET Reply #3 – July 09, 2017, 10:56:04 am Glad it has improved! 1 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #4 – July 09, 2017, 11:50:17 am First run for the day only lasted 20 mins. I'll keep you posted how the day goes. FINGERS CROSSED! X
Re: ONAN EMERALD PLUS 4000 GENSET Reply #5 – July 09, 2017, 01:01:59 pm Most common cause is air in the fuel line from deteriorated rubber hose. One section is on top of the fuel tank, and the other at the generator end. The one on the fuel tank is the most troublesome. When ours needed replacement, the generator would run if the fuel tank was over 3/5ths full, but unreliably below that.Steve 1 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #6 – July 09, 2017, 01:10:02 pm I'm going to crawl under it and check it then TY. 2nd try lasted 7 mins.
Re: ONAN EMERALD PLUS 4000 GENSET Reply #7 – July 09, 2017, 01:33:42 pm KathyThere have been numerous posts on this forum over the years concerning the failure of the rubber hose (approx. 2" long) at the top of the fuel tank. It will require that the tank be lowered in order to gain access. That's a job best left to someone more adept than the average owner. When I had to have mine ('04 30'IB) replaced the technician not only replaced the rubber hose section but the entire fuel line from fuel tank to generator with a stainless steel fuel line in lieu of the plastic one that comes OEM. No problems since. 3 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #8 – July 09, 2017, 03:20:10 pm Your 2000 LD is right age to have rotted rubber generator fuel lines.The generator fuel supply line has two rubber sections of hose, one right at the generator and the other located on top of the gas tank.The top hose can be very difficult to replace as access is extremely limited or not available.The gas tank can be partially dropped, to allow room to access the top base and its clamps.This is not a job for amateurs, the tank is very heavy.If the gas tank needs to be dropped, to replace the top hose, consider replacing the fuel pump, at the same time.Larry 1 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #9 – July 20, 2017, 10:54:18 pm Quote from: Larry W - July 09, 2017, 03:20:10 pmYour 2000 LD is right age to have rotted rubber generator fuel lines.The generator fuel supply line has two rubber sections of hose, one right at the generator and the other located on top of the gas tank.The top hose can be very difficult to replace as access is extremely limited or not available.The gas tank can be partially dropped, to allow room to access the top base and its clamps.This is not a job for amateurs, the tank is very heavy.If the gas tank needs to be dropped, to replace the top hose, consider replacing the fuel pump, at the same time.LarryAH, Larry thanks for the reply. I cleaned the battery with Baking Soda and it runs great! Just ran it to Yosemite, no need for Generator on this trip but I want to maintain things before they go!ALL your tips are so much appreciated and I take them seriously! Thank You
Re: ONAN EMERALD PLUS 4000 GENSET Reply #10 – May 19, 2018, 07:08:18 pm Well, time for update. I put in 2 New House Battery's and one in Engine comp. Then replaced spark plugs, oil filter, oil, air filter and Fuel Filter. I checked fuel lines but to my eye they looked good. Neighbor has a mobile RV mechanic guy who came over and he checked line and it needed replacement. He said it probably had Air in line. Generator still stalls after 10 min with a new gas line and my mechanic said it must be Carburetor because fuel pump isn't hot after 10 mins. I have been doing a lot of reading on this and when I checked into getting a carburetor I have read it is no longer being made for this type of generator. Ugh.
Re: ONAN EMERALD PLUS 4000 GENSET Reply #11 – May 20, 2018, 08:54:10 pm Hi Kathy, I hope you needed new house batteries, and a new chassis battery, because they have nothing to do with your generator quitting. You had just changed the genset oil, air filter and oil filter, changing them again also is just a waste of money. Any generator that runs for seven minutes, can't have much wrong with it. Not a clogged fuel filter. I don't understand your neighbors diagnosis about the fuel pump being hot or not. The suspect piece of rubber hose isn't the piece by the generator. If it were to leak you would smell the gasoline dripping out of it, and the generator would keep running anyway. The suspect piece of fuel line as Larry and Rodney stated is at the top of the main fuel tank. It is under suction as the generator is pulling gas out of the tank. small cracks in the line will allow some air into the line, and after the generator uses up the gas in the downhill line, the genset fuel pump can't get enough gas into the generator. At that time it should stumble a bit and then quit. A way to verify this easily is to get a new (or known good gas line) , hook it up to the genset input gas line, and run that hose into a mostly full gas 'can', usually a two gallon red plastic container certified for gasoline. If the generator runs ok for an hour or so, or until it runs out the portable gas can, then that would indicate that top hose as the likely culprit. You didn't mention how full your gas tank is. Usually people notice that the tank has to be closer to full to get the generator to run, until even at maximum fullness it won't run. That is another indicator that the top hose is leaking air. Another thing to check is your air pre-heat switch. I could believe an over heating condition, if you have it set to 'Winter". I leave mine set to 'Summer' always. I'd have to look it up but I suspect the Winter setting would be for below freezing situations. RonB 3 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #12 – May 21, 2018, 01:38:49 am Quote from: RonB - May 20, 2018, 08:54:10 pm A way to verify this easily is to get a new (or known good gas line) , hook it up to the genset input gas line, and run that hose into a mostly full gas 'can', usually a two gallon red plastic container certified for gasoline. If the generator runs ok for an hour or so, or until it runs out the portable gas can, then that would indicate that top hose as the likely culprit.Have your mechanic run this test, to verify leaking fuel lines. It's cheap and easy to do.As said before, the top fuel line is probably rotted and sucking more air than fuel.The cure is to drop the tank far enough to access the fuel lines on top of the tank. Some models require completely lowering the tank.Dropping the tank to change the fuel pump and generator lines would be my best suggestion.Besides the generator's fuel line, change the emission hoses too.Fuel pump failure is common in older rigs, it's a lot better to change the pump on your own schedule .A fuel pump from Ford or Bosch is preferred.Larry 2 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #13 – May 21, 2018, 03:48:44 pm RonB and Larry your quick reply is really appreciated! I'll checking into it and let you know. A new Carburetor is considered to obsolete. Gas tank full and I live in So Calif so it's set to summer. As for batteries I replaced because the house ones were expanding a little and last replaced in 2011. The Chasis Battery was replaced in 2010. I have no leaking gas so when he showed me the hose I was surprised it hadn't leaked. So off to do other fuel line and emission hose and fuel pump!Update info soon.
Re: ONAN EMERALD PLUS 4000 GENSET Reply #14 – May 21, 2018, 09:15:56 pm Have your mechanic check to see if there is output voltage.After many tries at getting my Emerald 4000 Plus to work, it was learnedthat the voltage regulator was not working correctly. 1 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #15 – May 21, 2018, 11:15:04 pm Quote from: Kathy Van - May 21, 2018, 03:48:44 pm I have no leaking gas so when he showed me the hose I was surprised it hadn't leaked. So off to do other fuel line and emission hose and fuel pump!Update info soon.This isn't going to be an inexpensive exercise, verify first the fuel line is bad and leaking air.Your generator's problem may be caused by something else, long distance troubleshooting can be very inaccurate.Larry 1 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #16 – May 22, 2018, 10:12:28 am Thanks Larry and Jota. I knew when I bought this 2000 LD I would have to replace parts. I'll update next month. This weekend I'm taking grandkids to camp land in San Diego
Re: ONAN EMERALD PLUS 4000 GENSET Reply #17 – August 23, 2018, 03:49:50 pm UPDATE: Last RV Mobile guy said it was carburetor; I informed him I thought it was fuel pump after all the inputs on this forum giving tips. He said it would have to be dropped but I felt he was not correct considering he replaced the fuel line with out dropping. I decide to get someone elseI went onto Cummings website and found a certified mobile Onan mechanic. He came out and did not have to drop generator to get to fuel pump. Im pleased to say it is running great and with the air on for over 1 hour. Test will end in another hour. I'm so happy and appreciate everyone's input in this issue. Thanks Again and hope this helps others 4 Likes
Re: ONAN EMERALD PLUS 4000 GENSET Reply #18 – August 23, 2018, 06:41:29 pm Quote from: Kathy Van - August 23, 2018, 03:49:50 pmUPDATE: Last RV Mobile guy said it was carburetor; I informed him I thought it was fuel pump after all the inputs on this forum giving tips. He said it would have to be dropped but I felt he was not correct considering he replaced the fuel line with out dropping. I decide to get someone elseI went onto Cummings website and found a certified mobile Onan mechanic. He came out and did not have to drop generator to get to fuel pump. Im pleased to say it is running great and with the air on for over 1 hour. Test will end in another hour. I'm so happy and appreciate everyone's input in this issue. Thanks Again and hope this helps othersKathy, thanks for posting the end of the story.Chris 1 Likes
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