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ImaginaryNumber's avatar
Jun 19, 2013

2004 Trail Lite 235s - How to remove generator?

I am tearing what little is left of my hair out trying to service the Onan Microquiet 4000 KY generator in my Trail Lite. After new plugs, fuel test, spark test, Sea Foam, B-12 carb cleaner, a few shots of ether, and lots of help from other members

http://www.rv.net/forum/index.cfm/fuseaction/thread/tid/27025369/gotomsg/27030711.cfm#27030711

the best I get is a brief put-put of hopeful life then shut down after about 15 seconds with fault code 36. Seems to be fuel starved, but the pump flows fine.

At this point, either taking off the fuel solenoid or installing a new carb seems to require removal of the genset from the compartment and I have not done this before.

Does anyone have instructions for genset removal from this Trail Lite model? Does carb service/replacement require genset removal?

The Cummins service manual starts out with the placement of the forklift... as if I have a forklift in the closet.

Thanks.

2 Replies

  • I'm sure you've seen on yours what I'm going to post, but anyway...
    Here is a photo of one corner of the mounting on my Trail Lite.



    See how the main bolt is bent? They bent all four corners like that. If yours is like that, then I'm thinking you'll be better off to disassemble the rubber mounts. Whatever you have to do.

    Then probably a floor jack to lower the darn thing. Maybe with the RV up on blocks or jack stands first to create enough working room.

    I would try more Seafoam, or better yet, Sta-Bil Marine formula. Use the fuel hose to the genset to go directly to a container of gasoline with the Sta-Bil Marine mixed in at the clean up dose, or twice the dose. Try to get the thing to run. Then let it sit for a couple days, try it again. Repeat until it runs.

    Anything to keep from dropping the genset. PS, the fault codes can be misleading. It sure sounds like a fuel problem, probably a clogged passage or jet.
  • is the bottom of the compartment open
    will it drop down, a transmission jack might do the job

    our 6.2kw sits on two cross supports that are bolted in
    I replaced the four bolts with log pieces of "all thread" rod when i needed to replace the starter

    now i can lower the genset by loosing each rod 'a little at a time"
    until i have lowered it to the desired position

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