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Old 04-04-2014, 02:15 PM   #1
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Onan 7500 Diesel Generator HDKAJ

We are coming up on the next 1000 hour maintenance schedule showing that the engine V-belt and coolant hoses be replaced (along with the regular service). In order to do the belt and hose replacement requires the generator to be dropped and removed, which I don't have the facility/jacks to do.

I have always been particular about service intervals, but was wondering what others have found/done with the suggested belt and hose replacement times. Have you always stayed with the schedule or let it extend and if so, how long did you let it go.

Am well aware what Onan recommends, but ours has 1920 hours on it so there is no warranty issues.

Thanking you in advance for your input.

Tom and Barb
2000 Bounder 39Z
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Old 04-04-2014, 11:07 PM   #2
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I wonder about that myself as mine is approaching 1,000 hours and mine will have to be dropped also.

On a better note, I did see where a Onan had been running for 25,000 hours with nothing done other that oil and filter changes. This gives me hope.
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Old 04-05-2014, 01:15 AM   #3
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Our doesn't have that much usage yet, but we've been advised to run it until the belt actually breaks. The generator will self-protect when it overheats due to the belt having broken and it can be replaced at that time. We didn't told this on one of these forums, but by Cummins Midwest who did routine service on the genny after we bought the coach.
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Old 04-05-2014, 06:07 AM   #4
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Tom, does it have the original belt and hoses? If you need it for a trip or rally and you do not maintain it, it could let you down. Remember, like tires, age as well as hours of use play even a larger roll in lifespan of these parts. When I did mine, I replaced belt, all hoses, water pump, thermostat, all filters and fluids as well as adjusted the valve lash. I did not want it to break down on me boondocking in the middle of the Atlanta races. It didn't.
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Old 04-05-2014, 09:55 AM   #5
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Mike

I agree with your statement about needing it for a trip or rally and it could let me down. In answering your question, with the best info we have is that the Generator was removed in 2007 for a coolant leak and at that time it received a major service. The invoice copy we have from the previous owner show some king of SKU code and not p/n's so identifying the belt is not possible. The cost was over $1,300 and was done by Camping World, so I must assume the belt was replaced at that time.

The hours since that service are just less that 900 and since we bought the MH, I change the oil and filter annually, needing it or not, never putting the 150 hours on it in a year. Also, to assure reliability, I have the fuel and air filters on their recommended replacement intervals.

The purpose of my OP was to ask what others have done about the 1000 hour/5 year replacement cycle. If no one has experience letting the time/hour cycle expire without doing the service and with no problem, then I'll have it done. As many of us try to keep costs down, I too try to do as much as possible myself, but dropping the generator is something I don't have the facility or jacks to do.

As you correctly addressed, I know that rubber products, belts, hoses, tires, etc. do have a lifespan, I was wondering if others have extended it. You being a Certified RV Technician have a wealth of knowledge/experience and your input to this forum is valued by myself and others, so if you have additional thoughts on this issue, I welcome them.

Thanks for your input.

Tom and Barb
2000 Bounder 39Z

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Old 04-06-2014, 04:04 PM   #6
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All I can tell you is that we have the same generator which is now 14 years old and has <600 hours on it (just enough to account for exercising it). We had the coolant changed at the first service after we purchased the coach 3 years ago and were advised by Cummins/Onan not to bother with the belt until it breaks. Our generator also requires removal from the MH in order to replace the belt.
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Old 04-06-2014, 06:19 PM   #7
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Funny...

I am going through the exact same questioning. The genny is 7 years old and there is no evidence that the 5 year schedule of things (hoses, thermostat, Vbelt) has been done. Even a couple 2 year items are in need of being down but those are user serviceable.

I'm pretty cautious about these things being that we are full timers and really don't want them to break down due to lack of attention. Also, I don't want my service contract to disapprove a claim for the same reason.

I'm floating the work to 2 different shops for estimates. Let's see what comes back. LOL
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Old 04-06-2014, 06:30 PM   #8
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I had the same question with my previous coach, a 2002 Journey with the same generator with 1,500 hours. We 'Waldock' on longer trips so I really did not want to take the chance of having the Onan let me down while on a trip and be at the mercy of whomever I could find to fix it. So, I dropped the beast and did all the work myself.

It is not that hard to do. I got a motorcycle jack on sale at Northern Tools that worked like a charm. When I got the generator out, all the hoses looked OK but I replaced them anyway. The belt was full of cracks and looked like it would fail at any time. I also replaced the T-stat and the temp sensor which had a lot of crud on it (if it fails, it will tell the generator it is overheating, even if it is not, and force a shut down).

So, it is a matter of how much inconvenience you are willing to tolerate if the belt breaks when you really need the generator.

Do a search on the Winnebago forum and I have a thread with pics showing how I removed the generator and how the work was done. It is not that hard but not for someone with really novice mechanical skills.
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Old 04-06-2014, 06:30 PM   #9
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96 Onan 10KW...original belts and hoses.
If it ain't broke, don't fix it.
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Old 04-07-2014, 10:24 AM   #10
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I really envy the coach owners that have their Onans on a slide out tray in the front.

I have to get a torch and cut the bottom support bars off and jack mine down.

Seems like it would not have been TOO much trouble to originally fabricate a bolt up tray for the 99 HR gens. Really makes me mad...
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Old 04-07-2014, 10:42 AM   #11
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I did coolant, etc at 1k and apx 7 yrs, but did not do hoses or belt. Mine has somewhere over 1,200 on it now.
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Old 04-08-2014, 11:16 AM   #12
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I am getting an estimate from a facility that is fully Cummins/Onan certified for high level maintenance. With 7 years and only 750 hours they did NOT recommend hoses (unless they found something when taking the covers off) and thermostat but did recommend Vbelt and temp sensor.

I'm waiting for them to give me an estimate for the "full monti" and what they recommend before I make a final decision. My theory is that it may be cheaper in the long run for the full monti but I'm waiting for the estimates.
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Old 04-08-2014, 11:32 AM   #13
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Mine is a 2004 and has 250 hrs. When it is 10 yr old I recommend having it taken out and the belt replaced and if it isn't welded in, wash the engine and clean every thing, you can rent a transmission jack to lower it. I would write Cummins and ask specifically what is done during the 10K hr. The 7.5 weighs a bit less than 500 lb and I am going to look at my alternator as it quit but may just forget fixing it. I would take all cover bolts off it and put anti seize on them and torque them back.
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Old 04-08-2014, 01:57 PM   #14
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FWIW...from Onan the following is the recommend service intervals for the HDKAJ
  • CHANGE OIL & FILTER (ANNUAL OR 150 HOURS)
  • REPLACE FUEL FILTER (500 HOURS)
  • CHANGE AIR FILTER (ANNUAL OR 500 HOURS)
  • CLEAN SPARK ARRESTOR (ANNUAL OR 150 HOURS)
  • FLUSH COOLANT SYSTEM (BI-ANNUALLY OR 1000 HOURS)
  • REPLACE COOLANT PRESSURE CAP (BI-ANNUALLY OR 1000 HOURS)
  • REPLACE ENGINE V BELT (EVERY 5 YEARS)
  • CLEAN CRANKCASE BREATHER (EVERY 5 YEARS)
  • REPLACE COOLANT HOSES AND THERMOSTAT (EVERY 5 YEARS)

I Suppose there will always be a difference of opinion mostly divided by those that are PREVENTATIVE oriented (no guarantee that it still won't break) and those that that tend to fix it when it breaks.
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