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Old 06-11-2015, 08:28 AM   #1
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Onan RV QG 4000 generator issue

Not the normal issue for me!! I was checking fluids the other day on our 2012 Greyhawk 31DS. I noticed, when checking the generator, that the air filter was basically hanging out of the air cleaner assembly.
After further investigation, I discovered that the V-shaped piece of metal that the air filter sits on had snapped at the base. No idea why!! Does anybody know of a place that I can order a new air cleaner cover assembly?? It only looks to be about 2 bolts holding it onto the air cleaner.
Thanks in advance!!
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Old 06-11-2015, 08:39 AM   #2
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Send pix.


Did welds fail? Screws fall out? Metal parts break?


Pull the manual, find the exploded view diagram and check the number in the parts list. Call the 800 number with a credit card handy.
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Old 06-11-2015, 09:44 AM   #3
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Quote:
Originally Posted by mike837go View Post
Send pix.


Did welds fail? Screws fall out? Metal parts break?


Pull the manual, find the exploded view diagram and check the number in the parts list. Call the 800 number with a credit card handy.
Yes, the 2 prong legs broke at the base of the air filter "support". I may have tightened them too much when I replaced it last year.
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Old 06-11-2015, 10:12 AM   #4
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Either find the manual and the exploded view diagram or take the pieces to the dealer.

If you google your make/model and "parts", you should be able to find somebody that will sell you one.

If you have a weldor friend, nearby, they could repair it for you.
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Old 06-11-2015, 11:12 AM   #5
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Ok, the part that has broken is in the flange bolted to the carb. The left of the photo. Any ideas?
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Old 06-11-2015, 11:24 AM   #6
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The manual can be found at https://www.cumminsonan.com/www/html...s/981-0246.pdf


Page 18. Item #17 is the broken part?


It is Part #145-0687-02 or 145-0705-02 depending on which manufacturing variant you own.


Call Onan part at (800) 888-6626 and they should be able to send you a new one.
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Old 06-11-2015, 03:02 PM   #7
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Mike, thanks for all the help!!
Now that I've seen pics of the replacement part, I may try to fix it myself.
I'm thinking of getting some L-brackets and reattaching it with some screw/bolts.
Any thoughts?
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Old 06-11-2015, 03:03 PM   #8
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Replacement part.
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Old 06-11-2015, 03:26 PM   #9
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I'm guessing the spot welds failed.


Clamp the pieces together as they are supposed to go. Drill .0625 holes through both pieces and use #6 self-tapping screws to secure it.


Being me, I'd wind up firing up my TIG welder and then buying the replacement part after I burned through the thin metal.
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Old 07-13-2015, 09:12 AM   #10
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Mike, I finally resolved the issue. I ended up drilling out the spot welds. Then I used 2 L-brackets to bolt to the flange and then the "A" frame thingy sticking up for the air filter. I got a little fancy and used stainless bolts, washers, and used nylon lock nuts to hopefully help with vibration. We'll see how it holds up! Thanks for the help!
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