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Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P


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  #1  
Old 07-20-2019, 01:32:13 PM
jessejmc jessejmc is offline
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Default Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

I have a 2014 motor home with a Cummins RV QG 4000 generator, model number 4KYFA26100P.

It was having some issues starting, and after fiddling around a bit, we realized that the starter cable was loose. In our fiddling, it fully disconnected from the starter. I assume that the nut fell off and the wire wiggled loose, but I haven't been able to get eyes directly on it. The cable is definitely detached from the starter though.

No one has has been able to get their arm far enough back to re-attach it, and it looks like we're going to have to drop the generator out of the RV. It's under-floor mounted, and the bolts look pretty rusted. I might be able to manage this job but don't have a great setup for it and would prefer to avoid dropping it myself. This leads to some questions:
  1. Does anyone have a method for reattaching the starter cable that doesn't involve dropping the genset?
  2. What about cutting a hole in the back for access? There are some obvious downsides here, like re-sealing the cut to keep road grime out.
  3. A mechanic estimated 5 - 8 hours of work. Does that seem reasonable?

Thanks. Also, how do you thank a user for a post? I've looked all over but can't find a link or button to do so.
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  #2  
Old 07-20-2019, 01:58:13 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

You'r problem is the reason I will not touch one of those things. Anything major and the cover has to come off. Cutting holes in the cover will destroy the cooling system. 5-8 hours your mechanic is being kind to you.

Sorry Doc I had to answer this one.
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Old 07-20-2019, 02:01:29 PM
Wayne 440 Wayne 440 is offline
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

IF it was my job, I would figure on removing the set rather than some work around that might cause further issues later.

That said, I despise working on RV sets, most installations I have seen appear to have given zero thought to service or maintenance of the generator. If your "mechanic" has no previous RV experience, add at least 50% to his/her time estimate. Most of the time, dropping a set is an all day job.

---------- Post added at 01:01:29 PM ---------- Previous post was at 12:59:39 PM ----------

Billy, don't tell me the Doc has banned you from here....
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Old 07-20-2019, 03:41:16 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

Wayne. He didn't ban me just told me to go easy. Keep the blood pressure down. Stay away from Genajunk units.
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Old 07-20-2019, 06:24:39 PM
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Thumbs up Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

It may be easier than you think to drop the unit. The rig is only 5 years old so removing the bolts may not be as difficult as you think.
It sounds like you know what you're doing, you know what's wrong, and you know what this entails.
I think you should at least give it a shot. I mean, it doesn't work now so what have you got to lose? (Well, maybe an arm or a finger or two, but what the heck.)
Seriously, give it a try, just be careful.
Think of the feeling of accomplishment, not to mention the money you saved.
I say go for it.
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Old 07-20-2019, 06:51:35 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

Disconnect the electrical connections, fuel line, exhaust.
Put a few hydraulic or mechanical car jacks under it and remove the bolts, lower it equally, being 4 kW it can't be that heavy.
Low enough, move the RV, you might place the RV a bit higher on some wood beams or something. Be careful !!

Eric
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Old 07-20-2019, 08:15:05 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

Years ago when changing oil on wife's car I just drove it up on grass using sloped curb of apt parking lot, gave me ~ 8 inches more clearance. Not sure if my now fat belly would still fit under the car these days.

With rusted bolts I put a propane/air turbo torch on the nuts to heat them towards ~ red hot to expand them, then they come off pretty easy.

Big heavy duty vice grips are good to hold the nut, or a box end wrench.

Dad used to put penetrating oil on few times a day for 3 days for rusted exhaust pipe nuts and they came off.

Of course the easier solution is put/hammer on a socket then use 1/2 inch drive breaker bar on them and just apply mussel to shear them off. Lot quicker and easier as long as you can get at the nut to replace it. No good if it's a tapped hole. Old worn out smaller sockets are good to hammer on heavily rusted smaller bolt heads and nuts.
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Old 07-20-2019, 08:32:23 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

lokay5 and eric s are right on. I have dropped a 4 BGE out from under an old junked RV in 1/2 hour. 4 bolts and some wiring.
BE CAREFUL as the sets are heavy. A type of jack that would work well is a motorcycle jack. https://www.ebay.com/itm/PALM-SPRING...YAAOSw301dBXUB
Depending on the hours on that generator, you might consider replacing the starter while you are in there. I just worked on a 4KY Thursday afternoon doing an oil service on it. Set has a TOTAL of 206 hours on it. I replaced the starter due to failure at 150 hours. They are nothing more than a cheapo lawn mower starter. You should also keep a good eye on the OIL level. This owner only put 50 hours on it since I last serviced it and never checked the oil level. I checked it BEFORE I drained it and the oil level was at the bottom of the stick.
No offense but these sets are NOT Onan's finest. The made a SINGLE cylinder, 3600 rpm set that only holds 1.6 quarts of oil with NO oil filter. My 2001 4BGE twin runs at only 1800 rpm, holds 4 quarts of oil and has an oil filter. Never burns any oil.
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Old 07-20-2019, 08:52:33 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

4KY is 174 pounds..... not going to hold it up with one hand. Set up some type of jack to lower/raise it.

When working on heavy/high force things I've always found it much easier and controlled to think it thru and let something else do the mussel work
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Old 07-20-2019, 11:39:14 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

Old joke, but it's likely not that unreal.

People with these 1.6 gal oil gens......... that are told their engine is seized say.......but it was ONLY down 1/2 qt

Keep an eye on your oil level.
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Old 07-21-2019, 12:37:58 AM
Wayne 440 Wayne 440 is offline
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

The KY holds 1.6 quarts, worse than that the 2.8KV holds 1 quart of oil.
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Old 07-21-2019, 01:44:59 AM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

Quote:
Originally Posted by len k View Post
Old joke, but it's likely not that unreal.

People with these 1.6 gal oil gens......... that are told their engine is seized say.......but it was ONLY down 1/2 qt

Keep an eye on your oil level.
The one I worked on the other day had less than a quart of oil left in it...and it doesn't leak. I am using Valvoline 5/40 full synthetic. Would you guys recommend anything different?
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Old 07-21-2019, 01:58:20 AM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

ONE quart? That's ridiculous!
I'd be runnin' some 40W in the summer and 20W in the winter!
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Old 07-21-2019, 02:02:42 AM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

I only see it about every 3 years.
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Old 07-21-2019, 02:36:19 AM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

I'm just repeating Yoda's joke.
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Old 07-21-2019, 04:40:01 AM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

Watch out what kind of jacks you drop it with they may not clear the bottom of the rv. Do some measuring you may have to drive it or pull it up on blocks. Don’t ask me how I know.
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Old 07-21-2019, 06:21:11 AM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

If you don't have much equipment, replace the mounting bolts (1by1) by 4 threaded rods and lower the thing on the 4 nuts.
Combine this with a jack to lower it inch by inch, can't fall.

Eric
Only works if it is not bolted sideways.
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Old 07-22-2019, 06:57:10 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

Thanks to everyone for their input. I'll pick up a motorcycle jack and make the attempt later this week. Will post how it goes.
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Old 07-22-2019, 08:10:13 PM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

Quote:
Originally Posted by jessejmc View Post
Thanks to everyone for their input. I'll pick up a motorcycle jack and make the attempt later this week. Will post how it goes.
I don't know if anyone welcomed you here but WELCOME!

We LIKE pictures. I think you will be very surprised at how easy it will remove. Take your time, the first time, and lower it and it will then make it easy to remove wiring and fuel line. MARK wiring by writing it down or what I do is take a picture or pictures with a cell phone BEFORE unhooking anything. By the way, How many hours are on the set? If you are over 200 or more, the valve clearance will need to be checked.
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Old 07-23-2019, 10:50:06 AM
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Default Re: Onan KY-P under-floor removal Cummins RV QG 4000 4KYFA26100P

I'll also throw out a suggestion. The weight is not even, one end is a little heavier so keep that in mind when you are unbolting and lowering the unit. Try to lower it as even as you can, we found out the hard way on a little larger RVQG 7000.

The 100% best way to remove them, if there is clearance and you have access to one, is to use a forklift. I believe the installation manual even shows that method.

The second time I removed ours, we did it that way.

Pictures would be good too. You may be lucky like us and be able to get it out the compartment door vs dropping it to the ground.
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