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Old 03-15-2012, 02:08 PM   #1
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Onan 7500 diesel question

The dip stick on this generator has a yellow plastic tip about 3" in length which is used to probe the oil level. The last couple of inches snapped off, inside the filler tube. My question is this: can this large piece of plastic move to a position to foul or obstruct oil flow? I haven't pulled the cover yet, so I do not know if the tube can be removed without major disassemble. Advise is welcome.
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Old 03-15-2012, 03:12 PM   #2
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This sounds like a call or visit to Cummins is in order before you start the genset again. I do not know for certain, but would guess that there is nothing to keep that piece from falling into the lower crankcase where it could be thrown up into the churning crank and rod ends. As it gets beat up small pieces could become lodged in lubricating channels and block flow. Big dollar repair would surely follow.

Let us know what Cummins says so we will know the next time this comes up.
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Old 03-15-2012, 04:43 PM   #3
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Yep, that plastic piece is a recipe for disaster I fear.
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Old 03-15-2012, 06:45 PM   #4
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Drain your oil and see if you can find the piece.....with luck it will come out when you drain it.
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Old 03-15-2012, 08:41 PM   #5
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Fairly certain it is lodged in the tube. There is a definite blockage when I try to insert the remaining part of the level "wire". The drain hole is about the same size as the broken-off tip anyway.

Dadgummit! I was just trying to be a good maintenance guy and this is my reward.
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Old 03-16-2012, 09:25 AM   #6
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Had the same thing happen to me. The broken tip was was lodged in the tube at the block. I was able to fish it out by using a piece of wire. You will have to take off all of the cowling around the generartor just to be able to get to it. The new dipstick is about $20. Good luck

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Old 03-16-2012, 11:38 AM   #7
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As a thought - Can the tube be removed? Is it screwed in or pressed. If threaded you might be able to remove the tube along with the part.
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Old 03-16-2012, 12:34 PM   #8
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Dodged the bullet

The fill tube is a rubber hose and is clamped on the engine with a one-time clamp. I was able to remove the side panel and use a dremel to cut the clamp off. The plastic tip was lodged in the engine side tube and easily pulled out. Looks like the diameter of the tube is such that it prevents the plastic end piece from entering the oil pan.

Now to wait for the rain to stop and reassemble the panel/oil filter and fill with fresh oil. Next step, procure a replacement dip stick.

Thanks for the advise gentlemen.
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Old 03-16-2012, 02:59 PM   #9
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Great news, and thanks for sharing the final resolution. Did you just go with a standard. Hose clamp for reassembly?
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Old 03-16-2012, 04:21 PM   #10
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Quote:
Originally Posted by SVTotem View Post
Great news, and thanks for sharing the final resolution. Did you just go with a standard. Hose clamp for reassembly?
I did just that. Had some quality SS clamps laying around and found the perfect fit. The local Bankston store actually had a dip-stick in stock ($28) and it is noticeable easier to slide in and lock in place.
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Old 03-16-2012, 04:57 PM   #11
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Sounds like you are good to go, and we all learned something for when it is our turn.
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Old 03-16-2012, 05:10 PM   #12
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I guess it would be advisable to closely examine the tip of the dip stick every time it i s out. Mine snapped right at the upper mark and at the transition from round to flat profile. I'll wager if I had been paying attention, I would have seen a crack developing before this fiasco.
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Old 03-16-2012, 06:52 PM   #13
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I also thank you for the update. Good outcome.

I did my generator service yesterday and was happy to see my dipstick was just fine.
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Old 03-17-2012, 11:36 AM   #14
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I'm glad you worked that out. It is a great idea to take a look at the plastic end of the dip stick for cracks - which I'll do this morning.
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