2022 Forester 2441DS Generator Question

[mcmilsw]

So have a 4KY-26100R Onan 4KW Gen Set in my Forrester Classic 2441DS. I've had the carb and fuel pump replaced by the dealer and that resolved the run for 15 min and die issue.

However I still have an issue with it running under a load and it sputters and stops like its running out of gas. I've "youtubed" this thing to death.

There's a gentleman that I work with who has a very similar unit the only difference is the length of the unit but has the same exact Gen Set. When I described the issue I was having and he stated that his issue was resolved when the dealer (Camping World) made an adjustment to the governor.

I have yet to find anyone saying this, but after looking at the service manual it seems like it's worth a check.

Any Gen Set Experts care to weigh in?

 

[BehindBars]

It was reported on the forum a similar problem that was the result of a pinched fuel line between the fuel tank and the generator. Do some searching on the forum for that thread.

 

[mcmilsw]

Yes sir I did that inspection last week while adding some sumo springs I followed the line from the gen set all the way back to the tank as far as I could couldn’t see any signs of pinching was really hoping that was going to be it

 

[Twinboat]

Load the generator up as much as you can to get it acting up

Then shut it off and drain the carb bowl to see if it's starving for gas. Of the carb bowl is low, get a clear peice of fuel line to watch for air bubbles in the flow, while running. That's a loose connection drawing in air.

 

[kenandterry]

Not sure if this even matters but……

I have exactly the same Onan genny in my Sunseeker.

In the attached photo, notice where my setting is for altitude adjustment.
My home base is 260’ above sea level, but it has never been adjusted for any of my travels anywhere so far on the Eastern seaboard.

 

[billwww3]

it was my 2020 3011DS that had the pinched genny gas line. You really could not see the pinch from observation underneath. I had to poke around inside the frame rails to figure it out. Three zip ties holding leveler hydraulic lines through holes in the frame had also gone around the shielded gas line. i think normally they must not take that path.
Strangely it took 3 years for this problem to appear. i speculate the gas line hose must have softened over time and then collapsed to restrict (not prevent entirely) the flow.
The clear gas line suggested is an excellent debug option. I added a clear filter which showed the problem for me. this has the added benefit of showing when the carb is fully primed with full float bowl as the filter will fill (almost but not totally) at that point.
i was at the point of ordering and replacing the fuel pump, which would have been a lot of effort (or money if i didn't DIY it) and still unsuccessful.
In my debug i discovered that unhooking the gas line from the fuel pump in the genny will result in gas free flowing from the tank. surprising to me as i thought the pump would have been required to draw gas to that point; but not. Unplug your fuel line and check the flow - it should be quite a lot from a 5/16" line!! get a bottle to catch it, you'll need it.
and good luck!!
*edit - you could also blow back through the fuel line to possible unblock the line

 

[Mr Brian]

Some of you will find this longwinded story interesting (or even familiar) - and I'm eager to hear your opinion...

We had a similar experience with the Onan 4000 generator in our 2020 Forester 3011 at the four year ownership mark, with nearly 200 hours of service. The generator worked flawlessly up to that point, and was exercised every 21 days under load for at least 45 minutes, and received all scheduled service, including regular oil and air filter changes.

The problem first surfaced while camping with a sudden shutdown after about 45 minutes of running under light to moderate load with the rig level, at 76F ambient temperature and a nearly full tank of fuel in the motorhome. I offer those last points to clarify it was not an obvious overheat or fuel source issue. It never surged or sputtered, just suddenly quit.

I started it up again, and it only ran for about 10 minutes before shutting down. Such happened again, and again at different intervals within a one hour time span. The generator never sputtered or surged, just stopped running without an apparent reason.

I ran it a few more times both with and without load in the week that followed (level, similar weather and fuel supply) and it died multiple times between the 5 minute and one hour mark. I checked the Onan Generator Fault Code, and all it offered was the generic "36".

Though I use only Top Tier gasoline - and the motorhome motor was exhibiting no issues whatsoever, I decided to drive the motorhome until the fuel tank was nearly empty, and fill again. The generator issue continued.

Sensing it may have been a generator centric fuel system issue, and nearing 200 hours in service, I set aside time to service the generator, including checking on the issue at each step.

• Inspection of the fuel supply hose from the motorhome gas tank (no problem seen)
• Inspection of the fuel supply system and carburetor mechanicals within the generator housing (no problem seen)
• Replacement of the still frightfully clean generator air filter. The problem persisted.
• A two-hour full gallon 'can/hose direct to generator (including soak) cleaning of the generator fuel system (50% Seafoam / 50% gasoline). The problem persisted.
• Replacement of the generator fuel filter. The problem persisted.
• Replacement of the generator spark plug. The problem persisted.
• Oil change (identical to all previous changes with precisely 1.6 quarts of oil). The problem persisted.

As I had only spent about U.S. $60 at this point for what seemed reasonable and simple to perform maintenance items, my mind sadly wandered toward the only other "obvious" issues (carburetor, generator fuel pump and/or generator circuitry), the co$t, time and headache to replace them began weighing heavily on me. Especially since I heard of others spending well into the 4 digits without the problem being resolved.

While computer shopping for the best price on an OEM fuel pump, OEM carburetor and OEM circuit board (ouch!) that I might prove to need, I began an on-line search and found some intriguing mention of an oil over-fill issue highlighted in this widely viewed YouTube video (please see the comments):

https://youtu.be/vzXDlln8aUw?si=3AYumZqnfAz00qlm

IT WORKED (for me)!

With just a little less oil than I thought I needed, our freshly serviced generator has been running flawlessly for hours on end.

That's my U.S. $0.02, YMMV.

 

[miataroadster]

Some of you will find this longwinded story interesting (or even familiar) - and I'm eager to hear your opinion...

We had a similar experience with the Onan 4000 generator in our 2020 Forester 3011 at the four year ownership mark, with nearly 200 hours of service. The generator worked flawlessly up to that point, and was exercised every 21 days under load for at least 45 minutes, and received all scheduled service, including regular oil and air filter changes.

The problem first surfaced while camping with a sudden shutdown after about 45 minutes of running under light to moderate load with the rig level, at 76F ambient temperature and a nearly full tank of fuel in the motorhome. I offer those last points to clarify it was not an obvious overheat or fuel source issue. It never surged or sputtered, just suddenly quit.

I started it up again, and it only ran for about 10 minutes before shutting down. Such happened again, and again at different intervals within a one hour time span. The generator never sputtered or surged, just stopped running without an apparent reason.

I ran it a few more times both with and without load in the week that followed (level, similar weather and fuel supply) and it died multiple times between the 5 minute and one hour mark. I checked the Onan Generator Fault Code, and all it offered was the generic "36".

Though I use only Top Tier gasoline - and the motorhome motor was exhibiting no issues whatsoever, I decided to drive the motorhome until the fuel tank was nearly empty, and fill again. The generator issue continued.

Sensing it may have been a generator centric fuel system issue, and nearing 200 hours in service, I set aside time to service the generator, including checking on the issue at each step.

• Inspection of the fuel supply hose from the motorhome gas tank (no problem seen)
• Inspection of the fuel supply system and carburetor mechanicals within the generator housing (no problem seen)
• Replacement of the still frightfully clean generator air filter. The problem persisted.
• A two-hour full gallon 'can/hose direct to generator (including soak) cleaning of the generator fuel system (50% Seafoam / 50% gasoline). The problem persisted.
• Replacement of the generator fuel filter. The problem persisted.
• Replacement of the generator spark plug. The problem persisted.
• Oil change (identical to all previous changes with precisely 1.6 quarts of oil). The problem persisted.

As I had only spent about U.S. $60 at this point for what seemed reasonable and simple to perform maintenance items, my mind sadly wandered toward the only other "obvious" issues (carburetor, generator fuel pump and/or generator circuitry), the co$t, time and headache to replace them began weighing heavily on me. Especially since I heard of others spending well into the 4 digits without the problem being resolved.

While computer shopping for the best price on an OEM fuel pump, OEM carburetor and OEM circuit board (ouch!) that I might prove to need, I began an on-line search and found some intriguing mention of an oil over-fill issue highlighted in this widely viewed YouTube video (please see the comments):

https://youtu.be/vzXDlln8aUw?si=3AYumZqnfAz00qlm

IT WORKED (for me)!

With just a little less oil than I thought I needed, our freshly serviced generator has been running flawlessly for hours on end.

That's my U.S. $0.02, YMMV.

I don't have the issue...YET, but I appreciate you posting the zero cost solution! Thank you!!!

 

[Ralphietom]

Sunseeker 2400t mbs with a RVMP gen set runs perfect last time started but next time won’t crank even at the gen local panel. When pushing start button I hear a single click. Help any? Is there a hidden fuse.

 

[BehindBars]

Sunseeker 2400t mbs with a RVMP gen set runs perfect last time started but next time won’t crank even at the gen local panel. When pushing start button I hear a single click. Help any? Is there a hidden fuse.

When you hear the click, where does the sound come from? What is the voltage measured on your house battery(s), or what is their condition or state of charge? If you have an emergency start switch in the cab that connects the chassis and house batteries, what happens if you try starting generator with that engaged? What voltage is seen at the starter relay on the generator when attempting to crank? Possible bad cable connection, bad relay, dead batteries, etc.

 

[Bill and Gail]

Sunseeker 2400t mbs with a RVMP gen set runs perfect last time started but next time won’t crank even at the gen local panel. When pushing start button I hear a single click. Help any? Is there a hidden fuse.

I had the same thing happen. A mechanic at my SIL's shop found it was a bad ground to the generator. He found it using a jumper cable and grounded the gen set to a good ground area.

 

[mcmilsw]

I had the same thing happen. A mechanic at my SIL's shop found it was a bad ground to the generator. He found it using a jumper cable and grounded the gen set to a good ground area.

Bill and Gail that was the problem with this gen set tech didn’t find it at first as the unit ran then it started acting up and in checking connections he bumped the ground and noticed it loose it was tight enough to make an intermittent connection. Everything is good now

 

[mcmilsw]

Loose ground was the issue Cummins tech finally found it